sbir success stories at nasa glenn research center · nasa / tm--1999-209649 sbir success stories...
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NASA / TM--1999-209649
SBIR Success Stories at
NASA Glenn Research Center
Walter S. Kim and Dean W. Bitler
Glenn Research Center, Cleveland, Ohio
George M. Prok, Marie E. Metzger, Cindy L. Dreibelbis,
Meghan R. Howe, and George D. Novak
Omni Corporation, Cleveland, Ohio
December 1999
https://ntrs.nasa.gov/search.jsp?R=20000018018 2019-12-30T10:23:57+00:00Z
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NASA / TM--1999-209649
SBIR Success Stories at
NASA Glenn Research Center
Walter S. Kim and Dean W. Bitler
Glenn Research Center, Cleveland, Ohio
George M. Prok, Marie E. Metzger, Cindy L. Dreibelbis,
Meghan R. Howe, and George D. Novak
Omni Corporation, Cleveland, Ohio
National Aeronautics and
Space Administration
Glenn Research Center
December 1999
Trade names or manufacturers' names are used in this report for
identification only. This usage does not constitute an official
endorsement, either expressed or implied, by the National
Aeronautics and Space Administration.
NASA Center for Aerospace Information7121 Standard Drive
Hanover, MD 21076Price Code: A04
Available from
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22100Price Code: A04
Contents
Subsonic SystemsDual-Spray Fuel Nozzle for Low Emissions Gas Turbine Combustors ....................... CFD Research Corp.A Probability Density Function (PDF) Method for Turbulent Reacting Flow ............. CFD Research Corp.
Unstructured Density Based CFD Methodology for Gas TurbineCombustor Applications ............................................................................................. CFD Research Corp.
Materials
Durable Interface Coatings for Ceramic Matrix Composites ........................................ Advanced Ceramics Corp.A Software Tool to Design Thermal Barrier Coatings ............................................................ Deformation Control Tech.+ Inc.
Perfluoropolyether Lubricating Fluids .......................................................................... Exflour Research Corp.Non-Toxic. Resin Transfer Molding (RTM) Processable, High Temperature
Matrix Resin ............................................................................................................... Foster-Miller, Inc.
Fiber Optic Systems for Composite Process Monitoring and Control .......................... GEO-CENTERS. Inc.Processing of Metal Matrix Composites with Controlled Microstructures ................... MER Corp.NEKTON: Tool for Coating Process Simulations ......................................................... Nektonics. Inc.Innovative Laser Furnace .............................................................................................. Penn Laboratories. Inc.
Laser Float-Zone Process Improvements ..................................................................... Penn Laboratories. Inc.Oxidation Resistant Ti-6AI-4V-SiC Composite Materials by Ion-Beam Processing .... Spire Corporation
Perfluoropolyalkylether Fluid as High Temperature Lubricant ..................................... Ultrasystems. Inc.
Power and On-Board PropulsionAlternator and Suspension for Free Piston Stirling Engines ......................................... Clever Fellows Innovation
Consortium, Inc.
High Temperature, Silicon Carbide, Power Thyristor ................................................... Cree Research, Inc.
High Efficiency Proton Exchange Membrane Fuel Cell ............................................... ElectroChem, Inc.
High Temperature Oxidation-Barrier Coatings for Refractory Metals .......................... Electroformed Nickel, Inc.Composite Regenerator for Stirling Engine .................................................................. Energy Science Labs, Inc.Fresnel Lens Photovoltaic Concentrator Array ............................................................. ENTECH, Inc.
Lightweight Graphite/Aluminum (Gr/A1) Space Radiators forThermal Management ................................................................................................. Foster-Miller, Inc.
Light-Weight Flexible Thin Film Solar Cells for Space Applications .......................... International Solar ElectricTechnology
Flexible, Lightweight, Amorphous, Silicon Solar Cells Tuned lbr Air Mass Zero(AMO) Spectrum ........................................................................................................ Iowa Thin Film Tech., Inc.
High Volume Metal Organic Chemical Vapor Deposition (MOCVD) DeviceWafer Production ...................................................................................................... Kopin Corporation
Arc Reduction Procedures for Solar Cells .................................................................... Physical Sciences, Inc.
Electrocatalysts for High Efficiency Solid Polymer Electrolyte Fuel Cell .................... Physical Sciences, Inc.Solid State Micromachined Pump ................................................................................. Research International
Carbon Fiber Flywheel for Power Generation and Attitude Control ............................. SatCon Technology Corp.Improved Mirror Facet ................................................................................................. Solar Kinetics
High Efficiency, Radiation-Resistant Indium Phosphide Solar Cells ............................ Spire CorporationIndium Phosphide Solar Cells on Silicon Substrates ..................................................... Spire Corporation
Integrated Optical Voltage Measurement System ......................................................... Srico. Inc.Measuring Reversing Flow Pressure Drop in Stirting Engine Heat Exchangers ........... Sunpower, Inc.
Regenerative Solid Oxide Fuel Cell Technology Development .................................... Technology Management, Inc.Lightweight Structural Foams from Ceramic Materials ................................................ Uhramet
NASA/TM-- 1999-209649 iii
Instrumentationand Controls
High Temperature Combustion Diagnostic Method Utilizing Rayleigh Scattering ..... Aerodyne Research, Inc.Optimization of Silicon Carbide Production ................................................................. Aerodyne Research. I nc.
Turbomachinery Flowfield Temperature Measurement Linear Imaging Diagnostics... Aerodyne Research, Inc.Microscopic and Macroscopic Modeling of Layer Growth Kinetics and Morphology
in Vapor Deposition Processing ................................................................................. CFD Research Corp.
Blackbody High Temperature Optical Sensor ............................................................... Conax Buffalo TechnologiesHigh Temperature, Silicon Carbide. Power MOSFET .................................................. Cree Research, Inc.
Communications
Passive Temperature Compensating Attenuator ............................................................ EMC Technology, Inc.Near Hermetic Packaging Technology for MMIC Devices .......................................... Foster-Miller, Inc.
Advanced Monolithic GaAs IF Switch Matrix .............................................................. Microwave Monolithics, Inc.
High Efficiency, Low Cost Monolithic RF Module for SARSAT Distress Beacons .... Microwave Monolithics, Inc.Microwave-Compatible Superconducting Films ........................................................... Neocera, Inc.
Innovative High Speed Modem for Satellite Communications ..................................... SiCOM, Inc.
Turbomachinery and Propulsion Systems
Phase Doppler Particle Analyzer ................................................................................... Aerometrics, Inc.
Simultaneous Measurement of Temperature, Size, and Velocity of Drops in Sprays... Aerometrics, Inc.
Single Lever Power Control for General Aviation and Unmanned Aircraft ................. Aurora Flight Sciences Corp.Unstructured Adapted Meshes ...................................................................................... Creare, Inc.
Advanced CFD Tools for Designing Combustion Systems & Materials Processing .... Daat Research CorporationImproved Electroformed Structural Copper and Copper Alloys for Rocket
Components ............................................................................................................... Electroformed Nickel, Inc.
Real-Time Sensor Validation ........................................................................................ Expert Microsystems, Inc.Ice Detection Sensor System ......................................................................................... Innovative Dynamics, Inc.Fiber Optic Cable Feedthrough and Hermetic Sealing for Aerospace Environment ..... LiteCom, Inc.
Unsteady Triangular Mesh/Navier-Stokes Method for Aerodynamics of Aircraft ....... Nielsen Engineering &with Ice Accretion ...................................................................................................... Research, Inc.
Catalytic Ignition for Rotary Combustion Engines ....................................................... Precision Combustion
A Novel Approach to Catalytic Combustion ................................................................. Precision Combustion
Flow in Turbine Blade Passages ......................................................................................... Scientific Research Assoc., Inc.High Temperature Oxidation-Resistant Thruster Materials .......................................... UltrametHigh Temperature Turbine Blades ................................................................................ Ultramet
Structures
Design of Experiments Module ..................................................................................... AI Ware, Inc.
Autosolid ....................................................................................................................... Cadetron, Inc.
AUTODESIGN ............................................................................................................ Structural Analysis
Technologies, Inc.High Reliability Long-Term Lubricators ...................................................................... The Technology Part nership
Microgravity
A Capacitive Void Fraction Instrument for Two-Phase Flow in Microgravity ............. Creare, Inc.
NASA/TM--1999-209649 iv
SBIR Success Stories at NASA Glenn Research Center
Walter S. Kim and Dean W. Bitler
National Aeronautics and Space AdministrationGlenn Research Center
Cleveland, Ohio 44135
George M Prok, Marie E. Metzger, Cindy L. Dreibelbis,Meghan R. Howe, and George D. Novak
Omni CorporationCleveland, Ohio 44135
Abstract
This booklet of success stories summarizes the NASA Glenn Research Center's accomplishments and successes
by the Small Business Innovation Research (SBIR) and Small Business Technology' Transfer (STTR) programs.These success stories are the results of selecting projects that best support NASA missions and also have
commercialization potential. Each success story describes the innovation accomplished, commercialization of the
technology, and further applications and usages. The company name and the NASA contact person are identified to
encourage further interest and communication to occur.
Introduction
Congress legislated the Small Business Innovation Research (SBIR) and Small Business Technology Transfer(STTR) programs to ensure that the best innovative concepts become part of federal research and developmentefforts that benefit the nation. This has resulted in NASA receiving high quality research from small businesses to
meet specific mission needs as well as directly contributing to the nation's economy and industry. Successfulinnovations have enabled small businesses to grow, mature, and provide jobs for the nation by moving ideas from
the drawing board to the marketplace.
In 1982, Confess legislated the SB1R program under the Small Business Innovation Development Act. The
objectives established by law are: to stimulate technological innovation in the private sector, to strengthen the role ofsmall businesses in meeting federal research and development needs, to increase the commercial application of theresearch results, and to encourage participation of socially and economically disadvantaged businesses.
The legislation re-enacted in 1992 extended and strengthened the SBIR program and increased the emphasis on
pursuing commercial applications of SBIR results.
NASA, under the policy directive of the Small Business Administration, allocates 2.5 percent of its extramuralresearch and development budget to the SBIR program. The funding is to be used for research or research and
development during the first two phases of the three-phase process. The SBIR program phases and the
implementation of the program are described on the web site: http://www.grc.nasa.gov/WWWFfU/sbir/sbir.htm.
With the resounding success of the SBIR program, in 1992, Congress legislated the Small Business Research
and Development Enhancement Act, which created the Small Business Technology, Transfer (STTR) program. TheNASA STTR program is designed to convert the nations' investment in research carried out by research institutionsinto new commercial technologies for advancing economic competitiveness and high-tech development. NASA
allocates 0.15 percent of the extramural research and development budget to the STTR program. Like SBIR, the
funding is to be used for the first two phases of the three-phase process. The STTR program is described on the web
site: http://www.grc.nasa.gov/WWW/TU/sbir/sttr.htm.
NASA/TM--1999-209649 1
TheNASAOfficeofAerospaceTechnologyprovidesoverallpolicydirectionfortheSBIRandSTTRprograms,withtheProgramManagementOfficehostedattheGoddardSpaceFlightCenter.TheNASAFieldCentersidentifythetechnicalneeds,evaluateproposals,makerecommendationsforselections,andmanageindividualprojects.AllNASAFieldCentersandtheNASAStrategicEnterprisesworktogethertomeettheagency'sstrategicgoalsandmissions.
NASAGlennResearchCenter(GRC)devotesalargeefforttoensurethateachproposalreceivesafairandcompetentevaluation.TherecommendationforawardselectionisbasedonthehighestinnovationthatmeetsGRC'smissiongoalsandatthesametimehavethebestcommercializationpotential.
Thecommercializationofinnovationisemphasizedevenbeforetechnicaltopicsaredrafted.ThroughoutthefeasibilitydeterminationinPhaseI andtheresearchanddevelopmentinPhaseII,thecommercializationpotentialisevaluatedasanimportantcriterionforawardselection.Atthecompletionoftheresearchorresearchanddevelopment,theprogram/projectofficesandtechnicalstaffarehighlyencouragedtoenterintoPhasemactivitiestoutilizeandcommercializetheinnovation.Thesmallbusinessisalsoexpectedtousenon-Federalcapitaltopursueprivatesectorapplications.A comprehensivehandbookwithguidelinesandproceduresforinitiatingPhasemisavailableat:http://ehb2.gsfc.nasa.gov/sbir/fcpm.html.
The success stories were compiled to document and identify the innovative accomplishments and commercialactivities, primarily from the Phase II projects that have been completed for several years. These success stories are
the results of the collaboration by the small businesses and the Contract Officer's Technical Representatives (COTR)who managed the contracts. Each success story has been approved for public release by a signed release from acompany official. All the success stories are posted on the Internet at:http://sbir.gsfc.nasa.gov/SBIRJsuccesses/contents.htm.
The purpose of this booklet of success stories is to identify the successes achieved by the GRC's COTRs and the
small businesses. This booklet should encourage further usage and applications of the SBIR developed technologiesand also promote further commercialization of these SBIR products.
NASA/TM-- 1999-209649 2
SUBSONIC
SYSTEMS
SmallBusinessinnovationResearch
Dual-Spray Fuel Nozzle for Low EmissionsGas Turbine Combustors
CFD Research Corporation
Huntsville, AL
INNOVATION
A fuel nozzle that provides high turndown fuel-air ratio and
low emissions in small aircraft gas turbine engines
ACCOMPLISHMENTS
• Designed fuel nozzle using advanced CFD analysis
• Tested prototype nozzles at atmospheric pressure for lean
blowout
• Fabricated and tested selected fuel nozzle in full annular
combustor test at idle and simulated full power operating
conditions
• Demonstrated lean blowout fuel-air ratio of 0.003 at idle
conditions. This exceeds the current AST goal ot 0.005
COMMERCIALIZATION
• Received over $175K in contracts from industry to study
potential in AST combustors• Selected as candidate by GE for 70% NOx reduction regional
engine combustor program; fabrication and testing started in
1998. Received $500K in Phase III funding from GE
• If successfully demonstrated, nozzle has potential of being a
production engine part. CFDRC will give the rights of the fuelnozzle to a fuel nozzle vendor in exchange for royalty fees
_Ier_n _esearch: Cer=ier
A,:iv;_r,sea S_:a_eqc "eci,noio'_y
Prototype Fuel Nozzle
GOVERNMENT/SCIENCE APPLICATIONS
• Potential use in low emission aircraft gas turbine
combustors
• Basis for further development of tow NOx fuel-air mixers
for land based gas turbine engines and other industrial
combustion systems, e.g., burners, boilers, process
heaters, etc.
1_90 Pnsse II NAS3-26616 rev 9;9#
NASA Co_=t_ot - Cq_-Mi!'_g Lee
Comps-s} Cor tact - C_iff S.m:tP:
SmallBusinessinnovationResearch
A Probability Density Function (PDF) Method @'for Turbulent Reacting FlowCFD Research Corporation
Huntsville, AL
INNOVATION
A Monte Carlo simulation technique for turbulent
combustion and its viability for practical applications
ACCOMPLISHMENTS
• A Monte Carlo solution module for the composition PDF
was developed to solve finite-rate chemical kinetics in
turbulent flows
• The PDF module was coupled with a general purpose CFD
code, CFD-ACE
• The PDF module was validated against experimental data
for hydrogen and hydrocarbon combustion
COMMERCIALIZATION
• The PDF solution module has been incorporated into
CFD-ACE and is being used by BMW and other selectedclients on a trial basis
• The PDF solution module is also usable as an
enhancement for other finite-volume CFD codes, such as
CFD-FASTRAN
• The PDF solution technique is being improved andextended with additional NASA and CFDRC funding
Lew:_ -,_e._,eaqol3 _,erfer
Acvanced Subsonic Techr_oio§y
3-003
,,, i .... i
3000 .... _ ' :, Experimental Dot_ _
2500 _Monte Carlo PDF -_
_ . -pre¢crlbed PDP
j'\ ..... NO PDF 4
2000 .; '_,:,
500
0 1 2 3 4 5
fir
Monte Carlo PDF Solution Agrees with Experimental
Data (Piloted Jet Diffusion Flame) much Better than
Solutions Using Simpler Models
GOVERNMENT/SCIENCE APPLICATIONS
• Prediction of emissions in turbulent combustion,
especially automotive and aircraft engines and stationary
power sources
:9'],') Pn_.se II, NAS3-26608 3;'98
NASA C :,_tacl • ,<at10wen
Cemoany Contact - Dr Ar:,d,¢ Lec'-_ard
NASA/TM-- 1999-209649 5
SmallBusinessInnovationResearch
Unstructured Density Based CFD Methodology forGas Turbine Combustor Applications
CFD Research Corporation
Huntsville, Alabama
INNOVATION
A new methodology for efficient generation of large high-
quality tetrahedral and prismatic meshes for CFD gas
turbine combustor and other applications
ACCOMPLISHMENTS
Developed software package CFD-GEOM with:
• Automatic curvature based unstructured grid generation
on trimmed-NURBS geometry models
@ Interactive assignment of boundary and volume conditions,
directly on the geometry, configurable for various flow solvers
• Tetrahedral grid mesher for large grids (100K-300K ceils per
minute) based on Delauney and Advancing Front techniques
• Prismatic grid rnesher for resolution of boundary layers based
on Advancing Layers Method
• Direct interface to commercial CAD systems
COMME RClALIZATION
• CFD-GEOM is being marketed as a stand-alone product for
structured and unstructured grids, as well as in conjunctionwith CFDRC flow solvers
• Installed at more than 250 organizations worldwide for a
variety of CFD grid applications. The average license feeis ~$5K
CFD.GEOM, with a direct link to UniGrsphics, accepts
true CAD data without IGES translation and generates
complete unstructured grid systems with minimal user input
GOVERNMENT/SCIENCE APPLICATIONS
• Standard grid generation software for the National
Combustor Code (NCC) computational framework
• Several Phase III extensions by NASA and CFDRC with
NASA contributing $375K
Lew:s _._.sroh Center
Advar'ced Su_sor=i_s Tech_.ology3- 006
1993 "-'hase i[, NAS3-27632, 3/98
NASA Cortac - l_,_a_.-Sue_,' L!U
C:o!'r!pa_=V Co!'_lact - Dr, Vincent Hz_rtJmd
NASA/TM-- 1999-209649 6
MATERIALS
SmallBusinessInnovationResearch
Durable Interface Coatings
for Ceramic Matrix Composites
Advanced Ceramics Corp. (ACC)
Lakewood, OH
INNOVATION
An interface coating that protects fiber-reinforced
ceramic composites from moisture and oxidation at
high temperatures
ACCOMPLISHMENTS
• Developed a family of high temperature and doped
boron nitride coatings that offer orders of magnitude
improvement in interlace durability for SiC/SiC
composites
• Demonstrated that fibers in woven fabrics can be
coated as uniformly as fibers in tows
COMMERCIALIZATION
• Firm supplies durable interlace coatings on fiber tows
from a new scaled-up facility
• Sales of $100K to Fiber Reinforced Ceramic Matrix
Composites (FRCMC) developers in 1996, with
1997 sales estimated at $300K
• Three new jobs were created
Digitized Images of Composites and Cloth
GOVERNMENT/SCIENCE APPLICATIONS
• Major impact on the Enabling Propulsion Materials
Program of High Speed Research showed that the new
interface coatings are more than 1,000 times more durable
than the state-of-the-art
• Applicable to national programs aimed at ceramic
composites development for military and terrestrial
application
• Durability of interface coatings has been proven in glass,
SiC, and Blackglas'" matrices
Lewis Research Ce".ter
Mater als
!992 _hase il NA_3-2",z690 SS-!:_z 89:'
NASA Collacts - Serer_e _arr':er
SmallBusinessInnovationResearch
A Software Tool to Design ThermalBarrier Coatings
Deformation Control Technology, Inc.
Cleveland, OH
INNOVATION
Software that enables design of ceramic coatings
to enhance coating life and coated component life
ACCOMPLISHMENTS
• Successful incorporation of 5 main stress drivers into
Thermal Barrier Coating (TBC) model, including oxidation
• First fundamental description of the role of oxidation in TBC
failure
• Provided first basic statistical descriptors for quantifying
interactive material property effects
• Provided basis for NASA TBC design innovation, patent
pending
COMMERCIALIZATION
• In use to analyze test results and design TBCs for electric
power generation turbine applications
• Commercial contract in excess of $10K was initiated prior
to completion of Phase II work
• Strong commercial interest in future analysis based on the
success of an exploratory contract
• This SBIR project resulted in an increase in employment,
from 2 to 3 employees
Lews qesearch CePler
Materials
3-002
Coated Aircraft Gas Turbine Stator
Vane
GOVERNMENT/SCIENCE APPLICATIONS
• Presently in use to define failure mechanisms in TBCs
• Continued use to reduce costly experimentation while
developing new TBC concepts
• In support of NASA HITEMP and Hybrid-Hyperspeed
programs
!993 F_-ase I NAS3-27539 3'-)P
tIASA {or_tac_ - B_II Br=r'_ e',,
Company Col_tact - -_, L,/'_n _etg _So_I CD-9_-77105
NASA/TM-- 1999-209649 9
SmallBusiness_nnovationResearch
PerfluoropolyetherLubricating Fluids
Exfluor Research Corp.
A ustin, TX
INNOVATION
New perfluoropolyether fluids for use
at higher temperature (260°£;) and in an oxygen environment,
at lower costs than previous alternatives
ACCOMPLISHMENTS
• Development of a series of fluids with good low temperature
(-40°C) and high temperature (260oC) properties as well as
oxygen stability
COMMERCIALIZATION
• Company has leveraged this technical knowledge to expandinto specialty fluorocarbon chemical production for uses other
than lubrication
• Technology licensed to the 3M Company
• Received $750K Air Force contract for optimizing a chemical
structure for use in high perlormance jet engines
• Firm employment doubled as a result of SBIR activities
Lewis _ese,3rch Center
Ma'tu_i_ls
F F F F F
/i i i \ iI /--C--O--C--C--O--) -C-F
F--C--O--I I
F / / / /n F
Structure for perfluoropolyether
GOVERNMENT/SCIENCE APPLICATIONS
• Usetut in the electronic industry and in Space Shuttle and
high performance aircraft where lubricants are required
that have a wide liquid range and a low volatility
• Technology can increase the operating temperature of jet
engines, thus increasing engine efficiency
1984 Phase 2, NAS3-24_,56, SS-114; 8,_29,,'9E
NASA Cc,_[3ct - Will am R. Jor_e_
SmallBusinessinnovationResearch
Non-Toxic, Resin Transfer Molding (RTM)Processable, High Temperature Matrix Resin
Foster-Miller, Inc.
Waltham, MA
INNOVATION
RTM processable, high temperature
(Tg>6OO°F), low toxicity matrix resin system
ACCOMPLISHMENTS
• Developed matrix resin system by combining reactive
diluents with the NASA developed AMB-21 polyimide resin
• Lowered the viscosity of the base resin significantly,
decreased the amount of volatile by-products during cure,
and increased cured Tg of AMB-21
• Successfully fabricated demonstration composite cylinders
by RTM
COMMERCIALIZATION
• Estimated market for RTM processable PMR-15 substitute
is $20-40 M/year
• Formed Pyrogonn I.I.c. for commercialization of this and
related technologies
• Sample materials provided to McDonnell-Douglas, Dow-UT
NASA, and GE Engines, for testing and evaluation
Lews Research Cenler
M3.te_Fal$
3-029
FOSTER-MI LLER, INC.I_ Be,_r H_II Road
_'_altham_ MA 021_
Composite Cylinders Manufacturedvia new RTM
GOVERNMENT/SCIENCE APPLICATIONS
• This resin system could replace PMR-t5 as a high
temperature organic matrix for carbon reinforced
composites in aerospace propulsion systems and other
high temperature structural applications where cost
effective fabrication to near net-shape via RTM isdesirable
l'_'J- P_l_.se I N&S3- 27532, 12,'98
1_6 P_lase I_ NAS3- 27818
NASA Coni="tct - Mike Mea0or
Company Con[act - Joseph Boyce
NASA/TM-- 1999-209649 10
SmallBusiness
_nnovationResearch
Fiber Optic Systems for CompositeProcess Monitoring and Control
GEO-CENTERS, INC.
Newton Center, MA
INNOVATION
Fiber optic sensors for monitoring polymer matrix cure
state, temperature, and pressure
ACCOMPLISHMENTS
• Developed tiber optic sensors for up to 400 ° C
• Developed methods to imbed fiber optic sensors intopolymer matrix composites
• Methods of entrance and egress of optical fibers fromautoclaves and molds to instrumentation were developed
• A simple instrument capable of monitoring 16 fiber opticsensors was developed
COMMERCIALIZATION
• Received commercial, DOE, and DOD funding totaling$250K (Phase III). DOE work was on resin transfer moldedcomposites and DOD work was on monitoring the cure ofmolded explosives
• As a result of this SBIR, GEO-CENTERS further enhancedtheir business by purchasing a technical competitor,Micromet, Inc.
Polymer Matrix Cure Monitoring& Process Control System
GOVERNMENT/SCIENCE APPLICATIONS
• Important to NASA's Aeronautics High TemperatureMaterials (HITEMP), High Speed Civil Transport (HSCT),and Enabling Propulsion Materials (EPM) Programs
• Important to all military advance propulsion engineprograms
• Two new jobs were created
Le¢,_s Research Certler
!_slr:Jn_eqL_t oP= & _::;L-:'=I!oI$
19£7 Phase l,_&$2-258!7 S$-168 9_97
NAS _, O,3rll._ct - Kel!nelq ._o'_,ie._
Small
Businessinnovation
Research
Processing of Metal Matrix Compositeswith Controlled Microstructures
Materials & Electrochemical Research (MER) Corporation
Tucson, AZ
INNOVATION
A semi-continuous hallow cathode magnetron systemfor coating small diameter fiber within multifilament fiber
tow followed by matrix coating
ACCOMPLISHMENTS
• Developed fiber-spreading equipment
• Developed segmented hallow cathode magnetron coatingsystem
• Developed interracial coating for ceramic (AI203, SiC) andcarbon fibers
• Developed matrix coating (copper, superalloys)
• Developed consolidation techniques, and characterizedcomposite mechanical and thermal properties
COMMERCIALIZATION
• Produced variety of metal-coated fibers to variouscustomers for evaluation
• Sales and internal development of more than $575K
• Prepared and presented business plan to several strategicalliances and venture capital groups to raise $5.5M forelectronic heat sink applications_._e _q Res_81rch Cerlte"
3-023
MER Automated Fiber Spreader
GOVERNMENT/SCIENCE APPLICATIONS
• High temperature composite materials for aerospaceapplications
• For use as a heat sink spreader for electronics
• For general use in heat management applications
1993 Phase II NAS3-27543. 5,'99
N,C'_,A ,:.;_,ntact - Susaq Dra_'er
Camper':,/Contact - Dr .q O LcL_tly
NASA/TM-- 1999-209649 11
SmallBusinessinnovationResearch
NEKTON:
Tool for Coating Process SimulationsNektonics, Inc.
Cambridge, MA
INNOVATION
Powerful simulation software for the modeling and analysis
of a wide range of coating flows
ACCOMPLISHMENTS
• Produced a fluid dynamics computer modeling tool for
simulation and analysis of a wide range of coating flows
COMMERCIALIZATION
• Commercial version brought to market by Fluent, Inc. asNEKTON 2
• Product introduced computational fluid dynamics to thecoatings industry
• Developed annual revenue of $400K
• Superseded in 1996 by NEKTON 3.0 for industrialcustomers
• NEKTON 2 continues to be used in universities
Slide coating Analysis with NEKTON
GOVERNMENT/SCIENCE APPLICATIONS
• Software was used in the Surface Tension Driven
Convection Experiment (STDCE), a low gravity fluid
physics experiment flown on STS-50, June 1992 andSTS-73, October 1995
• NEKTON can be used to model coatings in such diverse
industries as paper, magnetic media, film and adhesives
Lewi_ P_sea!ch CE,!'_ter
Ma_e t!al. __9g0 Pha_e 2; NAS3.26725 SS.132; 5/!2/97
NASA Contact - Bldce RGsenthal
SmallBusinessInnovationResearch
Innovative Laser Furnace
Penn Laboratories, Inc.
INNOVATION
A high temperature laser furnace
Dahlonega, GA
for mechanical testing of ceramic fibers
ACCOMPLISHMENTS
• Furnace incorporates room temperature mounting grips and a
uniform hot zone with relatively sharp boundaries and
controllable length
• Furnace capable of selective heating of single crystal fibers attemperatures of up to 3000°C
• Capable of implementing tensile tests under thermal load
conditions
COMMERCIALIZATION
• Firm received a Phase III contract for $163K from Metal
Samples Co., Inc.
Lew_g Resee.rch Ceqler
Mate.rials
Laaer Fiber Test Sample
GOVERNMENT/SCIENCE APPLICATIONS
• Being applied to NASA's Advanced High Temperature
Materials Program (HITEMP), in Enabling Propulsion
Materials (EPM) Program, and part of the High Speed
Research Program (HSR)
• Useful to Navy programs such as High Temperature
Phase Diagram studies
•Fumace used at NASA Lewis Research Center for
ceramic fiber research
1990 Phase 2, NAS3-26663, SS- 133, 3x2";/97
t'_ASA Cot, tact - Aii Saver
NASA/TM-- 1999- 209649 12
SmallBusinessInnovationResearch
Laser Float-Zone Process ImprovementsPenn Laboratories, Inc.
Dahlonega, GA
INNOVATION
Laser heated Melt Modulation TM technique
for ceramic fiber growth
ACCOMPLISHMENTS
• A furnace was designed and constructed to evaluate
laser heated ceramic fiber growth
• Multi-Wave TM pyrometer was developed for use in thisfurnace
• Pyrometer measures temperatures up to 3000°C in an area
as small as 75 microns, at a distance of 30 mm lrom the
target, with field of view approximately 2,000 microns
COMM ERCIALIZATION
• The Multi-Wave TM pyrometer, Multi-Wave TM HT-1C, is
currently commercially available
• NASA Lewis purchased two Multi-Wave TM pyrometers forfiber research at a total cost of $30K
Lewis Research L_er:ler
t'_ate risls
Laser Heated Fiber Growth Furnace
GOVERNMENT/SCIENCE APPLICATIONS
• Technology applied in NASA's High Temperature Engine
Material Program(HITEMP)
• USAF Office of Scientific Research is applying the
technology at the Wright Laboratory Materials Directorate
in the Edge-Defined Film-fed Growth (EFG) project
_98'5 Phase 2. NAS3-25944 SS-I_:J 2,24 9;'
NASA Contc',ct - ,_, i Sa'yer
SmallBusiness_nnovationResearch
Oxidation Resistant Ti-6AI-4V-SiC CompositeMaterials by Ion-Beam Processing
Spire Corporation
Bedford, MA
INNOVATION
Developed silver-based antimicrobial coatings for reducing
bacterial adhesion and proliferation on medical devices.
ACCOMPLISHMENTS
Demonstrated significant reduction in bacterial growth andcolonization on treated medical device surfaces
COMMERCIALIZATION
• Foundations of the antimicrobial coating technology were
developed under NIH and NSF grants and contracts.Continued work with NIH includes development of silver-based
antimierobial coatings for additional medical device applications,
• Earlier, the NASA SBIR Phase I contract contributed to theestablishment of Spire's ion beam assisted deposition (IBAD)
processing capabilities, upon which the antimicrobial coating
technology is based
• Spire currently processes over ten thousand medical device
components annually, resulting in several hundred thousanddollars in annual revenues
• Broad medical device applications, i.e. various catheters andother implantable medical devices, are being pursued with
significant growth expected over the next few years
• Increase in employment of 4 people
Le_.',=s _e_e;J'c_', Cerlter
Materi_,i'_
3-011
An#microbial IBAD silver coated
medical device components
GOVERNMENT/SCIENCE APPLICATIONS
• Potential uses in limiting device-related infection
for military applications/personnel
• St. Jude Medical is currently using the Antimicrobial
Coatings on prosthetic mechanical head valve suture
rings
1987 P"lase I t'iA.S3-ZS326 6:9£
NASA Cc,r'tact -James Smia ek
C_mpam., Cot'.tact - Rof_ Sct _.ll_!ck
NASA/TM-- 1999-209649 13
SmallBusinessinnovationResearch
Perfluoropolyalkylether Fluid asHigh Temperature Lubricant
Ultrasystems, Inc.
Irvine, CA
INNOVATION
Perfluoropolyalkylether fluids for lubrication capable of
performance between -50 and 316°C in the
presence of metals in oxidizing environments
ACCOMPLISHMENTS
• End-capping perfluoropolyalkylether chains with phospha-s-
triazine rings has produced fluid stability up to 316°C
• The new fluid also reduces degradation in the presence of metals
or under boundary lubrication and resists metal corrosion
• Evaluated a series of perfluoropolyalkylether fluids and greases
and developed performance guidelines
COMMERCIALIZATION
• Phase II report is used nationwide as guidance data for
lubricating greases and fluids, with company researchers
recognized as technology leaders
• Commercial applications include aircraft instrument bearinglubricant, computer memory disc surface lubricant,
vacuum pump oils and base stock for specialty greases andantiseize compounds
• Ultrasystems was absorbed by Lubricating Specialties Co.,Technology Products Division
• Received two Air Force contracts - one contract is worth$600K
Lewis Research Center
Materi,_Js
(06H5) 2t
N _ P" N
I II
RtOF2C _-N /CO F(OF3)OO3 F7
Structure for Perfluoropolyalkylether(Phospha.triazine capped)
GOVERNMENT/SCIENCE APPLICATIONS
• NASA applications include potential replacement of fluids
currently used in space instrumentation as wetl as
advanced aircraft lubrication
• Used in satellite guidance systems including
Geostationery Operational Environmental Satellites
(GOES); Television Infrared Observation Satellite
(TIROS); Earth Radiation Budget Satellite (ERBE);LANDSAT series
1983 Phase l i, N&$3-24632, SS- 115. TJ96
NASA Com.;let - Wd!iarn R Jones
NASA/TM-- 1999-209649 14
POWER AND
ON-BOARD
PROPULSION
SmalIBusiness Alternator and Suspension for @innovation Free Piston Stirling EnginesResearch
Clever Fellows Innovation Consortium, Inc.
Troy, NY
INNOVATION
A compact alternator/motor with reduced size and
mass and high efficiency that hasunlimited service life
ACCOMPLISHMENTS
• Produced a commercial prototype solar power generator
using STAR TM alternator/motor
• Constructed and demonstrated a working model for a
cryogenic cooler with STAR TM alternator/motor
• Demonstrated the STAR TM alternator/motor for uses as a
motor in a gas or air compressor
COMMERCIALIZATION
• Licensed Cummins to build and market a solar powered High-efficiency affordable reciprocating motor
generator, this project recently sold to Kombassan, a Turkishfirm GOVERNMENT/SCIENCE APPLICATIONS
• STAR" alternator/motor units sold around the world, $900K in • Solar dynamic power for future use in Space Station
sales in 1995 • STAR TM motor could be used on cryogenic coolers in test
• Contract with New York state for $395K to develop gas fired programs throughout NASA
generator • Combined with Thermoacoustic engine to produce ultra-
• Sold multiple licenses for cryogenic refrigeration services reliable generator for micro co-generation products
utilizing STAR TM based cryogenic coolers
Lew:_ =[esearcl:Car,tar 199_,P_ase 2 _',AS3-266_3SS-4"_;:8'97Si)aca F'o_'.erTechn:,log'; P,b\S,_,CoFi3ct- iIan -iV T_ieme
SmalIBusiness High Temperature, Silicon Carbide,Innovation Power ThyristorResearch
Cree Research, Inc.
Durham, NC
INNOVATION
A process for producing high performance power
Thyristors in Silicon Carbide (SIC) capable of
operating at 350°C
ACCOMPLISHMENTS
• Demonstrated the first power thyristor in SiC
• Fabricated high-performance Thyristors in SiC that passed1000 hour test at 350°C
• Operated SiC thyristors to temperatures as high as 500°C
• Achieved world record SiC power level of 4.2 kilowatts
COMMERCIALIZATION
• Increased SiC material and device sales by >$3.8M
• Created 14 new jobs and saved existing jobs
• Initiated tremendous worldwide interest in the area of SiC
power semiconductors, resulting in multi-$M programs in
SiC MOSFETs for government and commercial tabs
• Total market potential for SiC Power Thyristors would be
>$200M
Lew:s "qasearchCartarSpace Power3-022
Microgreph of a 10 Amp
4H-SiC Power Thyriator
GOVERNMENT/SCIENCE APPLICATIONS
• Will be used in military electric vehicles, i,e., electric tanks,
more-electric airplane, and shipboard power distribution
• Applicable for high temperature power conditioning in
spacecraft and will reduce weight and size of spacecraft
• Can be used to replace Silicon power devices in power
circuits for large electric vehicles and locomotives, and for
solid state power distribution of electricity for utilities
• SiC Thyristors offer much lower switching losses than
silicon devices in theses applications. Potential power
savings of :>$1 B/yr are possible
t'_91 P_._seII NA$3-2_'_9279'9_NASA Contact- Gere Sot!w._lzeCortlD-'_[qvCor_tac_- Jo!T t' _,'.!ir/!ojf
NASA/TM-- 1999-209649 17
SmallBusinessInnovationResearch
High Efficiency Proton ExchangeMembrane Fuel Cell
ElectroChem, Inc.
Woburn, MA
INNOVATION
Self humidified, high reactant utilization fuel cell
stack for operation with H2/O 2 reactants
ACCOMPLISHMENTS
• Development of an "off-the-shelf" commercial fuel cell as part
of ElectroChem's product line of research supplies and
instruments to the fuel cell community
• ElectroChem, Inc. has made advancements in their design of
fuel cell stacks. As a result, they will be able to manufacture
larger fuel cell stacks (500 cm 2) which will deliver up to 2kW of
power in addition to their smaller fuel cell stacks (50 cm 2)
• The ElectroChem, Inc. Proton Exchange Membrane (PEM) fuel
cell can operate at high reactant utilization, does not need
external reactant humidification, and can operate at
atmospheric pressure
COMMERCIALIZATION
• System integration work proceeding for other applications such
as back-up power systems, recreational vehicles, and stand-
alone regenerative power systems
• Can be used in rural electrification and in underwater vehicles
i!ii_iii_:i!i_i!i!'
GOVERNMENT/SCIENCE APPLICATIONS
• Study of fuel cell operation in upper atmospheric scientific
balloon for NASA Wallops' Balloon Program
• Could be used in remote power applications for the
defense industry
• Commercial sales of $53K for several units to NASA for
use in atmospheric studies as part of a SBIR Phase III
Lewis Rese;_rcb Cer'_t'3r
S__',ace P÷we! Tecbr:ology_J92 Phas_ h. NAS3-27242, SS-180. _!,'9"*
NASA Contacl - Dr. Patr, cia Loyse!ie
SmallBusinessinnovationResearch
High Temperature Oxidation-BarrierCoatings for Refractory Metals
Electroformed Nickel, Inc.
Huntsville, AL
INNOVATION
Eleclrodeposited iridium as a high density coating
to prevent oxidation of the refractory substrate and
insure long life in severe thermal environments
ACCOMPLISHMENTS
• Using the iridium coating over rhenium substrates prototype
radiation cooled attitude control thrust engines, such as
would be employed in satellites for maneuvering,
accumulated hot firing cycle life to 14 hours at 3400_F, has
been demonstrated by NASA Lewis Research Center
COMMERCIALIZATION
• Sales to date have totaled $107K
• A strategic alliance has been formed between Rhenium
Alloys Inc. (to supply rhenium chambers by an improved
powder metallurgy process), Electroformed Nickel, Inc. (to
provide a high integrity iridium oxidation barrier coating)and TRW (to design, qualify and market the product)
• A full time engineer has been added to the professional
staff to manage the new coating process
• TRW anticipates a widespread use of this process in a
product aimed at world-wide commercial satellite customersLew=s "-qesearch Cenler
Space _ower
3-018
Iridium plated lOOLb Rhenium Thrust Chamber
GOVERNMENT/SCIENCE APPLICATIONS
• USAF Phillips Laboratories has show an interest in this
coating process for rocket nozzle inserts to extend the life
and range of missile devices. Such an insert was
fabricated and successfully fired by Edwards AFB
• Interest in these coatings has also been expressed byLawrence Livermore National Laboratories
1989 Pqase II. NAS3-26256, 9/98
NASA Contact - Robe't, ,Jan_ovskv
Comp_rly Cot:tact - Gle_'t Malone
NASA/TM-- 1999-209649 18
SmallBusinessmnnovationResearch
Composite Regenerator for Stirling EngineEnergy Science Labs, Inc.
San Diego, CA
INNOVATION
A process for carbon fiber flocking on a carbon substrate
to produce high radial and low axial thermal conductivity
at high temperatures (1000°C)
ACCOMPLISHMENTS
• Development of a carbon-carbon composite matrix Stirling
engine regenerator providing high temperature capability and
high radial, low axial conduction
• Developed a carbon fiber flocking process to fabricate the
composite matrix regeneratorExample of Flocked Carbon Fiber
COMMERCIALIZATION
• Sales o! $1.8M in 1995, half of the sales were generated by
carbon fiber flocking GOVERNMENT/SCIENCE APPLICATIONS
• Expansion of manufacturing facility by over 40% and increase • Compliant heat transfer interface and composite phase
in staffing by 33% change material for advanced refrigerators/freezers for SpaceStation and Space Shuttle
• High conductance thermal interface gaskets lor use inaerospace thermal management and electronics packaging • Black surfaces for stray light suppression in spacecraft
instruments• Transverse reinforcements for delamination resistance in
composite materials used in primary aircraft structures
Lewis Research Cente-
M;_teria s
19_9 _3.se 2, NAS3-2_249, "-_S-41 42,9_
_'4ASA L'Orl -.'iC_ - Diar!e Cl_!pma'_
fnnovationBUSinessSmallFresnel Lens PhotovoItaiCENTECH,inc.C°ncentrat°r Array @Research Keller, TX
INNOVATION
Domed/Arched refractive concentrator system
providing higher efficiency at lower weight and cost
ACCOMPLISHMENTS
• Developed both Point-Focus Mini-Dome lens and Line-
Focus Cylindrical Lens Arrays for space power application
• SCARLET array (derived from line-focus lens concept)
provides spacecraft power at one-half to one-third the cost
of current arrays
COMMERCIALIZATION
• Over $1 Million in Space Lens sales to date to Boeing, AEC-
Able Engineering, and others.
• More than 20 new jobs were created at these companies
• Approximately $10 Million in space array sales to date by
ENTECH's customers
• SCARLET arrays now being commercialized/marketed by
AEC-Able Engineering Team
• $350K in Phase III funding from NASA Lewis
SC,_Ce Pc'we" Teci_r ologv
SCARLET Space Array
GOVERNMENT/SCIENCE APPLICATIONS
• NASMUSAF/Boeing PASP+ (Photovoltaic Array Space
Power plus Diagnostics) experiment flown in 1994 - firstsuccessful demonstration of ENTECH lens concept in
space
• BMDO/NASA Lewis SCARLET 1 Array successfully built
and space qualified for METEOR satellite
• 2,600 watt SCARLET 2 array to provide power for JPL's
New Millennium Deep Space One Mission launch in 1998
19_5 [-_hase I1:NAS3 25!92 1E'97
NASZ', Cc, ntact - f',4ichae P:SZCZOr
NASA/TM--1999-209649 ! 9
SmallBusiness_nnovstionResearch,
Lightweight Graphite/Aluminum (Gr/AI) SpaceRadiators for Thermal Management
Foster-Miller, Inc.
Waltham, MA
INNOVATION
Lightweight metal matrix composites (MMCs) withsuperior heat removal for structural radiators and thermal
management of electronics
ACCOMPLISHMENTS
• Designed and produced Gr/AI radiator panel with built-in
heat-pipe housing
• Demonstrated substantial weight and thermal performance
over baseline radiator components. Electronic substrate
provided 10% reduction in weight and 50% improvement in
performance. Radiators provide a 50% improvement in
weight and/or performance
• Designed, produced and demonstrated substantial benefits in
terms of heat removal and weight for Gr/AI as a substrata forelectronics
COMMERCIALIZATION
• Commercial sales for MMC substrates for electronics will
be over $40K for 1997
• Two new jobs were created
• Army funded a program for $550K to place inserts in MMC
components
Radiator Panel from MMC
GOVERNMENT/SCIENCE APPLICATIONS
• Gr/AI MMCs have application in dimensionally stable
spacecraft structure and optical platforms, and they have
thermal management application in gas turbines and
rocket engines.
• Use of these MMCs as a substrate in electronic products
will reduce cost and improve reliability of radars, satellites,
and other electronics intensive systems
• Samples of MMC electronics substrates are beingsupplied to government prime contractors for evaluation.
Keen interest has also been expressed by aerospacecontractors in MMC radiators.
L_swa$ Re$oarC:l Ce!'lbH
Space F'owe, Tecr_qoiogy
1992 Phase il NA83.27385. 11,97
NASA Contact - Kari BakeF
SmallBusinessinnovationResearch
Light-Weight Flexible Thin Film Solar Cells
for Space ApplicationsInternational Solar Electric Technology
Inglewood, CA
INNOVATION
Light-weight, high power density thin filmsolar cells on flexible substrates
ACCOMPLISHMENTS
• Produced polycrystalline copper-indium-disetenide (CIS)solar cells on flexible metal foils
• Work led to an Air Force-supported project that resulted inthe demonstration for the first time of CIS solar cells with
over 1 kW/kg power density on polymeric substrates
• Received innovation award from NASA
COMMERCIALIZATION
• A joint experimental effort is in progress with a
multinational company to produce the cells on a specific
light weight substrate
• Received over $3M Advanced Technology Program
contract for communications applications of these devices
Flexible Copper-lndium-DiselenideSolar Cells
GOVERNMENT/SCIENCE APPLICATIONS
• Very attractive for many NASA, commercial and militarysatellite power applications
• Useful for terrestrial applications where light weight andflexibility of solar cell is desired
Lewis Researcri Cer_ter
SDaCP. c-ower
3.027
1990 Fhase 11 NAS3-26815, 1£;98
NASA Contact - e4en_, Curlis
Cornpeny Cor:tac! • Bulem Baso}
NASA/TM-- 1999-209649 20
Small
Business
Innovation
Research
Flexible, Lightweight, Amorphous, Silicon Solar Cells
Tuned for Air Mass Zero (AMO) Spectrum
Iowa Thin Film Technologies, Inc.
Ames, IA
INNOVATION
Tandem amorphous silicon modules
on a polyimide substrate
ACCOMPLISHMENTS
• Optical modeling to calculate thicknesses of device layers for
maximum AMO solar spectrum absorption
41, Deposition parameters for device layers optimized for
pedormance of amorphous silicon solar cells in space
• Construction of a dedicated tandem amorphous silicon
deposition machine
COMMERCIALIZATION
• Company sales as a result of SBIR were $200K and growing
• ITFT increased from a few employees to 12 full time and 8 part
time employees
• Phase III monies totaled $4.7M from several government and
private sources. The DOE National Renewable Energy Labs
(NREL) is the largest government contract.
• Private investment provided the financing of a just completed
production lacility
Lewis Re_,,.=arch Center
Splice POw. =_ Tecqr=ologv
Flexible Amorphous Silicon Modules on
a Polyimide Substrate
GOVERNMENT/SCIENCE APPLICATIONS
• ITFT amorphous silicon modules for space applicationsare under evaluation at the NASA JPL
• ITFT modules are under evaluation at the NREL/DOE
Laboratory for terrestrial applications
• Companies evaluating our material for space applicationsinclude Lockheed-Martin and TRW, which includes testing
in space
1989 Phase ii I'_AS3-262_4 *_'P;'
!,_ASA C+;ql&,+-t - Der,!_s ;food
BusinessSmallHigh Volume Metal Organic Chemicalinnovation Vapor Deposition (MOCVD) DeviceResearch Wafer Production
Kopin Corporation
Taunton, MA
Advanced heterostructure devices for
microwave communications :
ACCOMPLISHMENTS
• Introduced the first carbon-doped Heterojunction Bipolar
Transistor (HBT) Device Wafer to commercial market
• Introduced InGaP HBT Device Wafer for High Reliability Epitaxial Layer Structure
Applications
COMMERCIALIZATION
• Leading provider of HBT Device Wafers in world wide
markets
• Commercial sales increased 6x, from -$3M in 1995 to
est. $18M in 1998
• HBT L-Band Power Amplifiers (PA) Rapidly Penetrating
Cellular Handset
GOVERNMENT/SCIENCE APPLICATIONS
• HBT Circuits used as high power X-band radar
applications
• HBT will migrate to higher frequency microwave
communication applications
t.e_+'_is Rese3rch Ce_te
3-0" 7
!98_ #ha_,e I; NAS3-2544g '),9£
_98_ Ph&s_ I NAS3.25.94.8
NASA ,",_/_tact - Deqr s F!o(_
COrP[3a'ly OOrlt_+'[ - Dr Nore:_ °aq
NASA/TM-- 1999-209649 21
SmallBusinessinnovationResearch
Arc Reduction Proceduresfor Solar Cells
Physical Sciences, Inc.
Andover, MA
INNOVATION
Solar cell construction procedure that reduces frequency
of arcing in high voltage solar cells
ACCOMPLISHMENTS
• Developed construction method for solar cells to reduce high
voltage solar cell arcing
4, Developed UHV test facility and methods for evaluating the
mechanism of arcing in high voltage solar cells in Low Earth
Orbit (LEO)
• Successfully tested reduced arc frequency solar cells duringshuttle mission
COMMERCIALIZATION
• Established testing service for alternate solar cell designs
• Sales of more than $100K for testing service
High Voltage Arcing
GOVERNMENT/SCIENCE APPLICATIONS
• NASA purchased test panels for $15K which were
tested successfully on Space Shuttle STS-62.
• Very useful to Space Station
• Applicable to any LEO power system
LeW_ -Qese._rcJ-' Cel_!er
Sp&ce Power Tecrlr_oJo_y1967 Phase _t NAS3-25797. SS-_ 7E.. 9:97
NASA Ceqta.t,'. - Da',,ia SqytJer
SmallBusinessInnovationResearch
Electrocatalysts for High Efficiency SolidPolymer Electrolyte Fuel Cell
Physical Sciences, Inc.
Andover, MA
INNOVATION
Electrochemical catalyzation (ECC) technique for
producing high performance proton-exchangemembrane electrodes
ACCOMPLISHMENTS
• Improved ECC process
• Application to high surface area, high utilization, high catalystloading electrodes demonstrated
• Specific activity improvement demonstrated
COMMERCIALIZATION
• The improved process is being qualified for commercial fuel
cells by manufacturers that include International Fuel Ceils
and Energy Partners
• Phase III funding of $190K obtained from the Department ofEnergy and the State of Florida
• ECC Technology can be used to develop and manufacture
lower cost, higher performance Polymer-Electrolyte
membrane (PEM) fuel cells
Lewi_ Resea_c_ Center
So, ace Power Technology
m
PSi s ENictmchlml_cal CIIllllyz|t)or_ Process
PSI'$ Electrochemical Catalyzation Process
GOVERNMENT/SCIENCE APPLICATIONS
• Applications include long term Lunar and Mars
missions, underwater autonomous vehicle propulsion,
and terrestrial remote, and portable power
!990 #ha_e I NAS3-26699, SS-_91,9,_97
NASA Co[_lact - Dr. Ri,;ha_d [_aldw:r'
NASA/TM-- 1999-209649 22
SmallBusinessinnovationResearch
Solid State Micromachined PumpResearch International
Woodinville, WA
INNOVATION
Micromachined pump with no moving parts
ACCOMPLISHMENTS
• Pumping technology incorporated into a four-channel solid-state
lluorometer
• A patent is pending for this product, Analyte 2000, a portable,
automated immunoassay system for the detection of toxins and
pollutants
• This final product combines technology from another SBIR
award from Johnson Space Center
COMMERCIALIZATION
• Commercial applications include deteclion of toxins and
pollutants in coal mines, as well as an early warning smoke
detector for industrial applications
• Company tripled in size from 10 to 30 employees with the
hiring of 16 new engineers and scientists at a total cost
of $2.44 M
Le_,,,i5 Rg_ea_cq Ce:Tte r
Joi':q_,0"7 S_ace Cente_
Spe.ce Powe_ Technoiogv
Micromachined pump
GOVERNMENT/SCIENCE APPLICATIONS
• Micromachined pump used for cooling electronics in
space
• Circulation of heat transfer fluids on spacecraft
• Monitor for fire hazards and hazardous gas releases
within shipboard magazines on naval warships
799C_ Phase I t'iASa-2E£1£ SS-_ 31 3'20,9","
199:! Pl-a{e I - JSC
NASA Contact - Karl BaKer
SmallBusiness_nnovationResearch
Carbon Fiber Flywheel forPower Generation and Attitude Control
SatCon Technology Corp.
Cambridge, MA
INNOVATION
A 2 Kw/hr carbon liber flywheel capable of
power over a speed range of 20,000-40,000 rpm
ACCOMPLISHMENTS
• The round trip efficiency of the energy storage wheel, including
power conditioning electronics, is expected to exceed 85%
• The flywheel is supported on magnetic bearings which reduce
the parasite losses of the system
COMMERCIALIZATION
• Technology is directly applicable to the flywheel energy storage
program SatCon currently has with Chrysler's Patriot project, a
high performance hybrid electric race vehicle, that uses
flywheel storage to improve the efficiency by load-leveling aturbine-alternator
• Pursuing customers such as public utilities for use as a load
leveling intermediate energy storage device, and for
uninterruptibte power supplies
SatCon Flywheel Energy Storage System
GOVERNMENT/SCIENCE APPLICATIONS
• Flywheel is aimed toward a combined energy storage and
attitude control system which can be used on ISSA as well
as all types of NASA, commercial, and military spacecraft
ranging from low power communication or observing
spacecraft to orbital platforms
• SatCon is committed to developing flywheel products for
automotive, industrial, utility and aerospace applications
Marshal Sp_,,:.e Fi=ght Cer"lef
Lew:s Research Cente"
Sp,=.ce ;_ov,'er Te,';r_r_3 o_.;y
198) Phase I . "_b9(:_ nl'ase : SS-gT: 8'_,!1,'9_
NASA Contact - Ra_ rBeach
NASA/TM--1999-209649 23
Small
Business
InnovationResearch
Improved Mirror FacetSolar Kinetics
Dallas, TX
INNOVATION IA spin coating process for depositing aluminum on an all metal
honeycomb structure to produce high precision mirrors
ACCOMPLISHMENTS
• Demonstrated high precision mirrors can be produced by
depositing aluminum on a metallic honeycomb by a spin
coating process
• Further improvements were validated in a 2 kW test
• Developed an ultra-lightweight scaled parabolic mirror
facet with a specific weight of 1.8kg/m2 with a refiectivity
greater than 85%
COMMERCIALIZATION
• Sale of $1 M to Harris Corporation to build panels for use
on Space Station
• Terrestrial applications include solar concentrators for
solar powered waste detoxifiers
• Created three new jobs
Solar Dynamic Ground Demonstration Unit
GOVERNMENT/SCIENCE APPLICATIONS
• Government uses include; Space Station, advanced
space telescopes and lightweight antenna dishes
• Very efficient, high quality concentrator is important to
NASA's Solar Dynamics Program for both space and
terrestrial applications
Lewis F'esearcrt Cein_er
S_ice Power Techr_o!oC_Jy
198"7 _hase i, NAS3-25632, SS-26.4,'_7_g7
NASA Cc!_tact J3me$ E Cal(ger3s
SmallBusinessmnnovationResearch
High Efficiency, Radiation-ResistantIndium Phosphide Solar Cells
Spire Corporation
Bedford, MA
INNOVATION
Space solar cells having superior radiation resistance for
missions in high radiation environments
ACCOMPLISHMENTS
• Achieved world record conversion efficiency (>19%) for
indium phosphide (InP) cells
• Confirmed radiation hardness by actual flight experiment
Photovoltaic Array Space Power Plus Diagnostic (PASP-
Plus)
• Basis for current proposal to NASA for a reduced-cost
concentrator arrayIndium phosphide Solar Cells
COMMERCIALIZATION
• Led to successful NASA and Navy-sponsored cell
development programs using 90% less expensive siliconsubstrates
GOVERNMENT/SCIENCE APPLICATIONS
• Long-life, reliable photovoltaic power for commercial,
military, and NASA satellites in medium-to-high radiation
environments (e.g., MEO, GEO, or high LEO)
Lewis Resear,"h Cerlter
5pace Power iechnc, iog y
1984 Prkase Jl; NAS3-24857. !2,'97
NASA Contact - Dennis F_ood
NASAFFM-- 1999-209649 24
SmallBusinessInnovationF_esearch
Indium Phosphide Solar Cellson Silicon Substrates
Spire Corporation
Bedford, MA
INNOVATION
Lightweight, reduced-cost solar cells for high radiation
environment space flight missions.
ACCOMPLISHMENTS
• Achieved significant reductions in cell weight (-50%) and
substrate cost (>90%)
• NASA program led to additional Navy-sponsored advanced
development
• Follow-on program achieved record high conversion efficiency
(-13%)
COMMERCIALIZATION
• Flight panel currently under construction for a high radiation
mission Space Technology Research Vehicle (STRV 1-C/D)
being funded by a $370K Navy contract
Satellite with Indium Phosphide on Silicon
Substrate Solar Cells
GOVERNMENT/SCIENCE APPLICATIONS
• Affordable photovoltaic power for long duration missions
in medium-to-high radiation orbits.
• Technology currently being evaluated by at least three
solar cell suppliers and users
Le'_',,:.¢;RP.._,P.a'Ci-= Cer_t£;
Sr-a_.e mower "-eCnrlO!Og,t
_':JST Phase li NAS3 25798 2'F _
_'JA_A L'_qtar.:! 3eqr=is F;OOd
SmallBusinessInnovationResearch
Integrated Optical VoltageMeasurement System
Srico, Inc.
Columbus, OH
INNOVATION
Voltage sensor probe that allows isolation from
electromagnetic interference by converting the
electrical signal to an optical signal
ACCOMPLISHMENTS
• Integrated optic high voltage probe with optical signaltransmission, eliminates the need for high voltage leads from
source to readout
• Optical isolation reduces the safety problems associated with
high voltage
• The problem of electrical noise and electromagnetic
interference was eliminated as well as problems associated
with vibration
• Improved measurement accuracy
COMMERCIALIZATION
• Large scale production of an inexpensive robust probe will beinitiated
• Over $1M in sales expected the first few years of production
• Electrical distribution companies will use this system in their
power distribution tacilities
I..ewi_ Rese_r_: P' C;e'_ter
Space Po_'.er Tect_qology
Voltage Sensor Probe
GOVERNMENT/SCIENCE APPLICATIONS
• Well suited to NASA's stringent requirements for
automatic control of aeronautic or space power
management and distribution systems
• Kennedy Space Center - for lightning and thunderstormdetection
• Space station power system
• Electromagnetic compatibility testing
• Physiological monitoring o! astronauts
13,93 Pq&se _, N'_S3-27273. SS-45, _',"9_
N._SA Cor_tact - _,_'lard P_tlersol_
NASA/TM--1999-209649 25
SmallBusinessInnovationResearch
Measuring Reversing Flow Pressure Drop inStirling Engine Heat Exchangers
Sunpower, Inc.Athens, OH
INNOVATION
A unique flexible rig for measuring pressure drop inoscillating flows
ACCOMPLISHMENTS
• Developed an oscillating flow test rig to measure pressurevariations in complex engine flows
• Provided insights into flow effects in Stirling engine heatexchanger
• Provided much improved understanding of one of the primarylosses in Stirling cycle machines
COMMERCIALIZATION
• Improved performance of both Stirling-cycle engines andStirling-cycle coolers; hence this SBIR has resulted in thecontinued support from private industry
• Resulted in another SBIR and a University grant that allowed rigmodification to also measure oscillating flow heat transfer inregenerators
• Information derived from measurements was incorporated intoStirling computer codes that are being used to design Stiflingengines and coolers by private companies
Oscillating Flow Test Rig
GOVERNMENT/SCIENCE APPLICATIONS
• Stirling engines are a leading candidate for dynamicspace power systems - Slirling has been chosen as abackup for the Advanced Radioisotope Power System(ARPS) being developed for deep-space missions
• Stiding engines are applicable for use in terrestrialdynamic power, including remote power generation andcogeneration
Le'_v5 Research Cerler
Space F'Owot TeChF_OlOgy
_984 _hase il NAS3-24879 tZ/97
NASA Cor_taq.i_, RO, Few _!'_d La!_llvTheme
SmallBusinessinnovationResearch
Regenerative Solid Oxide Fuel CellTechnology Development
Technology Management, Inc.Cleveland, OH
INNOVATION
Solid oxide fuel cell (SOFC) and electrolysis that iscombined into a high-efficiency energy storage system
Sulfur-tolerant integrated SOFC/relormer technology thatcan operate using common hydrocarbon fuels including
logisticfuels and biogas
ACCOMPLISHMENTS
• Improved system operation and efficiency
• Scalable fuel cell component technologies
• Integrated systems packaging
• Developed for small, low weight and volume applications
COMMERCIALIZATION
• Continued support from both commercial (EPRI, GRI,other) and govemment (DARPA, Navy, NASA, USDA,DOE) contracts to serve multiple portable and stationaryapplications operating multiple fuels including militarylogistic fuels and biogas
DARPA 500 Watt Portable Power System Mock-up
GOVERNMENT/SCIENCE APPLICATIONS
• Ultra-small, low maintenance, stationary electric powergeneration applications (down to 100 Watts) operating onmultiple sulfur-bearing luels
• Military (logistic fuel) portable and mobile applications
• Low earth orbit (LEO) and other satellite power applications
• Water electrolysis for the production of hydrogen
Glenfz _esearcb Center
Energy' C c,,r_ver,qlc,r:
3.032
1993 P_ase IL NAS3-2.7546. 2,'99
NASA Con[act - Malk Hoberecht
Company Contact - Senson F Lee
NASAfI'M-- 1999-209649 26
Small
Business
innovation
Research
Lightweight Structural Foams fromCeramic Materials
Ultramet
Pacoima, California
INNOVATION
Very lightweight ceramic foams as substrates
for reflectors used in space-based solar power systems
ACCOMPLISHMENTS
• Developed technology to produce lightweight open-cellstructural foams from ceramic materials such as boron
carbide, silicon carbide, and hafnium carbide
• Produced lightweight, high quality reflectors using siliconcarbide-hafnium carbide foam substrates with aluminum-
coated quarlz mirror faceplates
• Ultimately spun off foam technology into medical field, as
Hedrocel TM synthetic bone material
COMMERCIALIZATION
• Licensed medical foam technology to Implex (Allendale,
NJ), a manufacturer o! musculoskeletal implants. Implex
has invested $10 million in production facilities and
experimental trials. Implex 1996 sales were nearly $1.5
million, with 1998 sales projected at $20-30 million
• Formed joint venture, Cytomatrix (Cambridge, MA), to
develop biological cell growth medium using loam
technology
• To date, 6 jobs at UItramet, 30 jobs at Implex, and 4 jobs
at Cytomatrix have been created
Lightweight Mirror Structure with
Aluminum-Coated Quartz Mirror Faceplate
GOVERNMENT/SCIENCE APPLICATIONS
• Primary NASA application is in solar concentrators
tor advanced solar dynamic power systems
• Can also be used in solar collectors for ground-based
solar power systems
Ig86 mIiEL_e ii,NA_3-26_!_. SS-]77, _'g7
NASA/TM-- 1999-209649 27
INSTRUMENTATION
AND
CONTROLS
Small
Business
Innovation
Research
High Temperature Combustion Diagnostic
Method Utilizing Rayleigh Scattering
Aerodyne Research, Inc.
Billerica, MA
INNOVATION
A Dual-Line Detection Rayleigh scattering technique using
a copper vapor laser for non-intrusive temperaturemeasurements in combustor flows
ACCOMPLISHMENTS
,i_ Developed a Dual-Line Detection Rayleigh scattering
technique to allow subtraction of surface scattering
background noise from Rayleigh scattering signals
• Designed and tested an instrument using this Rayleigh
scattering technique for non-intrusive measurement of
combustor exhaust gas temperatures
COMMERCIALIZATION
• Provides a non-intrusive tool for dynamic time resolved
measurement of gas turbulence and temperature
• Technique could be used in research for density
measurement and mole fraction of gases
Research test data is available to industry
_..ew s ;_ese_.lr::b C+c_ter
I_$:rbr'per,tation & Cor_trols
Rayleigh Scattering Probe
GOVERNMENT/SCIENCE APPLICATIONS
System was delivered to NASA Lewis Research Center
where it was successfully used on a research combustor
The technique and research results were passed-on to
Polytechnic Universtiy and Air Force Wright Laboratories
for use in temperature and turbulence studies of gas
flows and for further development of the technique
19@5 ":_ha_.,e il NA93-246! 3 SS-"Tg, 9;97
NASf- Contact - Richard Eeashoitz
Small
Business
Innovation
Research
Optimization of Silicon Carbide ProductionAerodyne Research, Inc.
Billerica, MA
INNOVATION
Combining gas phase calculations with experimentalobservations ot surface reactions into a predictive model to
optimize chemical vapor deposition (CVD) of silicon carbide
ACCOMPLISHMENTS
• Developed a computer code to model epitaxial Beta-SiC
growth in a chemical vapor deposition process
41, A 2-D predictive model of Beta-SiC growth in a chemical
vapor disposition reactor was delivered to NASA Lewis
411,Co-authored a paper with Lewis comparing model with
experimental results from Lewis
COMMERCIALIZATION
• Code was used in development of a methane arcjet lor
space propulsion
4, Received $25K in development funding from the Navy and
$35K in commercial sales
• Computer models have application for improved high
temperature electronic devices
• Work done under this SBIR project is still cited by
researchers involved in SiC CVD modeling
• Received a related SBIR from Air Force Office of Scientific
Research (AFOSR)
L.ev,,,is F_esea_ :.r Center
il_strumerxatlOi*. _q_ Coqtrol5
3-001
41,
41,
Heated Susceptor in CVD Facility
GOVERNMENT/SCIENCE APPLICATIONS
The code was used by NASA Lewis to optimize
production of single crystal semiconductors for high
temperature electronic devices
Results from this SBIR are still used by researchers
involved in SiC CVD modeling
Silicon carbide is an important electronic matedal for
advanced aerospace applications that involve high
temperature, high power and high frequency
19E4 -:'b_se ii. NAS3-;,'389_ _S-I_0. 12,'97
NASA Cor.tact - i_,,!a ia KuczmarsK_
C_: m:_any ,':_;ontact - L.au,ie De_,n CD-9_-770:[i
NASA/TM-- 1999-209649 31
SmallBusinessinnovationResearch
Turbomachinery Flowfield TemperatureMeasurement Linear Imaging Diagnostics
Aerodyne Research, Inc.
Billerica, MA
INNOVATION
Non-intrusive measurement of gas temperature
and/or density for use in turbomachinery
ACCOMPLISHMENTS
• Demonstrated the feasibility of non-intrusive measurement
of temperature and density in a flowing gas stream
• Developed an optical measurement technique for
use in compressor flow fields
iJ
)
Linear Imaging Temperature
Measurement System Design
COMMERCIALIZATION
• $11 K Phase III funding for further development of the
temperature measurement system at Glenn's compressor
test facility
• A new approach for non-intrusive measurement of gas
temperature based on an O2-LIF technique has been
demonstrated at GRC as a result of the Phase III funding
• GRC may use additional Phase III funds for demonstration
tests in a compressor after reviewing results in the finalreport
GOVERNMENT/SCIENCE APPLICATIONS
• This technique will be used in the "Smart Green Engine"
Program
• Will be used in the NASA Physics and Process Modeling
Program (PPM)
• Useful in turbomachinery research over a temperature
range of 300K-500K
• Useful in research applications requiring non-intrusive
measurement of gas temperature
Gie!1", R_$garch Center
_nst_uq-erh:_l!J(;"
3-Q$4
1991 _hase !!, NAS3-27000, 6-99
NASA C,:.[_tacl - t,Aark _-', Wemet
Corn#a%' Con act - K#rt D Aqnen
SmallBusinessinnovationResearch
Microscopic and Macroscopic Modeling of Layer
Growth Kinetics and Morphology in Vapor
Deposition Processing
CFD Research CorporationHuntsville Alabama
INNOVATION
Simulation tool (CFD-FILM) to enable development of new
materials for semiconductor and opto-electronic applications,
as well as for structural and thermal barrier coatings
ACCOMPLISHMENTS
• Developed a Monte Carlo microscopic model to simulate
specific morphological characteristics of film growth such as
step bunching, thermal roughening, polytype growth,
growth uniformity, defect formation, etc.
• Created a commercial software, CFD-FILM, to analyze
morphology of growing films
• Validated the microscopic model against experimental
data for materials such as Si, diamond and SiC
• Coupled CFD-FILM with a general purpose macroscopic
transport/chemistry software, CFD-ACE
COMM ERCIALIZATION
• Contributed to increased sales of CFD-ACE to leading semi-
conductor equipment vendors and process designers(-$500K/year)
• CFD-FILM is marketable as a stand-alone module, as well as
an add-on module with CFD-ACE
• Application projects from industry and research projects from
government agencies
Simulation of Step Bunching in SiC Growth
(using CFD-FILM)
GOVERNMENT/SCIENCE APPLICATIONS
• Provides an enabling technology for advanced materials
such as GaN, GaAs, InP, and SiC
• Provides a base technology for extension to plasma-
substrate interactions in low pressure etch processes
LeWiS Research Cet_ter
Insbur_'er'tatiorl & Ool_[ro_$
3-005
1992 Phase _1 NAS3-27287. SS-, 2,'6,'_r-_
NASA Corl1_,ct - Amorl Chair or Maya Kuozmarski
Company Contact - D_ Ana.rltha Kdsqnaq
NASA/TM-- 199%209649 32
SmallBusinessInnovationResearch
Blackbody High TemperatureOptical Sensor
Conax Buffalo Technologies L.L.C.Buffalo NY
INNOVATION
An optical sensor system for gas pass temperatures
utilizing a thermally ernissive insert imbedded in
a sapphire lightguide
ACCOMPLISHMENTS
• Sensing element has a time constant less than one second, adiameter of 0.06 inches and has been tested at temperatures
up to 1500°C
• Calibrated sensor under static conditions against
therrnocouples, accuracy is estimated to be +18 ° C
COMMERCIALIZATION
• Complete optical sensor systems have been fabricated for
commercial use
• Large scale production of optical sensor systems for
commercial and government use is in progress
• A Phase III effort of qualifying this optical sensor system for
use commercially was financed by Electric Power Research
Institute (EPRI), GE Aircraft Engines IR&D, and NASA
• More than $500K was received for optical sensor qualification
and other commercial sales
Military Aircraft Fiber Optic
Exhaust Gas Temperature Sensor System
GOVERNMENT/SCIENCE APPLICATIONS
• Hardware was developed for the NASA Fiber Optic
Control Systems Integration (FOCSI) Program
• Development programs are ongoing for use of this
system in military aircraft and ground based power
generation turbines
Lt=v_:5 Re.-=earO" C_',,='
Iq,3t[_lm i.rm_ati_ & COd lr015
E986 mh._se I; t';AS3-25.451 SS-156 3,24,97
"JAS _,,Conta(t *-'.obe t Baumbi<:_:
SmallBusinessinnovationResearch
High Temperature, Silicon Carbide,Power MOSFET
Cree Research, Inc.
INNOVATIONA process for producing high performance powermetal/oxide semiconductor field-effect transistors
(MOSFETs) in Silicon Carbide (SIC)
ACCOMPLISHMENTS
• Demonstrated the first vertical power MOSFET in SiC
• Fabricated a high-performance MOSFETs in SiC that can
operate up to 300°C
• Received Patent on this technology
COMMERCIALIZATION
• Increased SiC material and device sales by >$3M
• Created 12 new jobs and saved existing jobs
• Initiated tremendous worldwide interest in the area of SiC
power semiconductors, resulting in multi-$M programs in
SiC MOSFETs for government and commercial labs
• Total market potential for SiC Power MOSFETs would be
>$2B
L.e.'_ s Research Cerlel
:r=51rurr_£fitaf or' _'!d C0qtrOiS
3" :.).?1
Durham, NC
Dr_ Con_ct
Cross-Section of a SiC Power MOSFET
GOVERNMENT/SCIENCE APPLICATIONS
• Will be used in aircraft engines
• Applicable for high temperature electronics in space craft
and will reduce weight and size of spacecraft
• Can be used to replace Silicon power devices in power
circuits for electric motors and power control, for electric
vehicles, robotics, and power supplies
• SiC MOSFETs offer much higher efficiencies than silicon
in these applications. Potential power savings of >$1B/yr
are possible
1986 Pqase tl. t4&S3-25986 9/98
NASA Co_tac_ - La_vrence _4a_,us
C :*r'npany C;;;ntac! - )onn _ tT'c:,_,r
NASA/TM--1999-209649 33
COMMUNICATIONS
Small
Business
Innovation
Research
Passive TemperatureCompensating Attenuator
EMC Technology, Inc.
Chert r Hill, NJ
INNOVATION
A family of passive high frequency temperaturecompensation attenuators (Thermopad ®)
ACCOMPLISHMENTS
• A 25% improvement in temperature compensation
• The development of high Temperature Coefficient of
Resistance (TCR) thick film materials
• High frequency attenuator designs
• Automated high frequency measurement development
• Power Sensing Termination (SmartLoad ®) development
COMMERCIALIZATION
• - $1 Million in commercial sales in 1997
• 10 new jobs at EMC Technology, Inc.
Thermopad ® Smartload ®
GOVERNMENT/SCIENCE APPLICATIONS
• Components are currently flying on four different military
and commercial satellite programs including:
- IRIDIUM, Motorola telecommunications satellite
- VMtSAT, European meteorological satellite
- INTELSAT, Global Star telecommunications satellite
- INMARSAT, Lockheed Martin telecommunications
satellite
Lewis Research Oente:
Tecl n,caL Area • Sa_e E:te Corql-qu_.icat or'. _
3-0! 2
1992 F_.aJe II , N_$3-27656. 598
NASA C;ontact -[_e!ald Cbom,:,s
Company CorT_ast -Joseph Mazzochette
Small
Business
innovation
Research
Near Hermetic Packaging TechnologyFor MMIC Devices
Foster-Miller, Inc.
Waltham, MA
INNOVATION
Excellent Electrical and barrier properties of Liquid Crystal
Polymers (LCP) are exploited to provide Light Weight,
Low Cost, Near-Hermetic Packages for High
Frequency Applications
ACCOMPLISHMENTS
Developed processes to fabricate low loss, controlled
impedance transmission lines on LCP films
Packaged and Tested a Triquint Low Noise Amplifier
(LNA) using flip chip technology. Coefficient of Thermal
Expansion matched LCP substrate did not require underfilling
Interconnected receiver circuit elements (mixer, LNA) on an
LCP substrate and tested up to 20 GHz
Packages are 50% less weight with potential to achieve 75%
reduction in cost compared to hybrid technology
COMMERCIALIZATION
• Triquint Inc. interested in using the technology to package their
integrated circuits
• Teledyne Electronic Technologies interested to be a vendor of
substrates to the industry
• Superex, a Foster-Miller subsidiary, created to commercialize
the LCP technology, added three new employees
Lew:s _esearO! Cer!ter
S_,el]lt e C o1_1Ti1_ri ct_! Jo r e
3-0_9
High Frequency LCP Package
GOVERNMENT/SCIENCE APPLICATIONS
• LCP technology is suitable for transmit�receive (T/R)
modules. Applications include NASA communicationsatellites, and other communication satellite systems
such as iridium, Teledesic, etc.
• Use of LCP technology for packaging will reduce the cost
and weight of air-borne and space-borne electronic
systems
• Keen Interest to extend the technology to digital, and
mixed signal applications and ball grid array, chip scale
and built-up laminate technologies
1992 Fqase _ NAS3-26968 SS- 5,'9_
NASA Cc.r'tac_ - Afroz Zama_
CompeRy C_r_tacI • K Jayarai
NASA/TM-- ] 999- 209649 37
SmallBusinessinnovationResearch
Advanced Monolithic GaAs IFSwitch Matrix
Microwave Monolithics Incorporated
Simi Valley, CA
INNOVATION
A 3x3 monolithic microwave integrated circuit (MMIC)
switch matrix implemented in gallium arsenide for
wideband (3.0 - 6,0 GHz) communications applications
ACCOMPLISHMENTS
• Monolithic implementation using gallium arsenide switching
devices achieved high isolation, low loss performance
• Modular design allowed cascading of switch matrices with
little signal degradation
COMMERCIALIZATION
• MMIC technology offered ten times reduction in size, weight,
and power requirements over competing technology
• A Phase III NASA Lewis contract for $1.23M was received
to develop a fully integrated 6X6 switch matrix
• A 6X6 switch matrix was delivered to NASA -Lewis
Research Center, which performed as specified
• Marketing this product led to substantial adjunct sales of
space flight GaAs MMIC based hardware
Lewis Research Cente_
C_mmunicatioqs
3-025
6 X 6 MONOLITHIC GaAs SWITCH MA TRIX
GOVERNMENT/SCIENCE APPLICATIONS
• Demonstrated that for future wideband satellites light
weight, low power switch matrices can be fabricated
• Provided a buitding block for future microwave integratedcircuits
1983 Rhase If. NAS3-2_252, 1W98
NASA Oontact - Gene _ujikawa
Corl1,_iny Co;_tact * Darfie! C!_er!
BusinessSmallHigh Efficiency, Low Cost Monolithic RF Moduleinnovation for SARSAT Dmtress Beacons •Research Microwave Monofithics Incorporated
Simi Valley, CA
INNOVATION IMiniature, ultra high efficiency GaAS MMIC
components lor Search and Rescue Satellite Aided
Tracker (SARSAT) Distress Beacons
ACCOMPLISHMENTS
• Developed ultra miniature Personal Locator Beacons
(PLBs)
• Utilize smaller, safer batteries without performance loss
COMMERCIALIZATION
• Microwave Monolithics invested $1.2M of company
resources after completion of Phase II and developed a
complete MicroPLB SARSAT Beacon
• Commercial Sales of this and related technology devicesexceed $1.1M to date
• Additional Government Sales of $300K directly resultedfrom the Phase II effort
• Substantially larger Commercial Sales projected
Lewls =,esearch Center
Comm_nicat_ons
3-0i6
MicroPLB SARSA T Beacon with Internal
Homing Signal and GPS Interface
GOVERNMENT/SCIENCE APPLICATIONS
• The MicroPLB is a vital safely device for Military and
Civilian Government personnel, providing rapid worldwide notification and Iocalion information in case of
emergency
1987 I:=_lase II NAS3-25712 , B',q'8
NASA Contact - Flbgert Kerc, zP,wski
Company Conta¢.: - Danie! Cn'en
NASA/TM-- 1999-209649 38
Small
Business
4nnovation
Research
Microwave-Compatible
Superconducting Films
Neocera, Inc.
Beltsville MD
INNOVATION
A process for growing high transition temperature
superconducting films of yttrium-barium-copper-oxide on
sapphire or lanthanum aluminate substrate
ACCOMPLISHMENTS
• Developed innovative pulsed laser deposition hardware
• Products developed in the process include manual multilayer
deposistion systems, target carrousel flange assembly,
substrate heater flange assembly, and programmable
substrate heater controller
COMMERCIALIZATION
• Initial sales include $55K for pulsed laser deposition
hardware and $750K for high temperature superconducting
film and equipment
• Sales of all the various products developed increased to
approximately $3 M
• Staff was increased from 3 to 15 people
110Vh.6_HZAC _oto, 15
Flange Assembly for
Pulsed Laser Deposition
GOVERNMENT/SCIENCE APPLICATIONS
• For microwave engineering, procedure will reduce phase
noise in planar microwave components such as local
oscillators
• Size, weighL and microwave loss will be reduced when
properly used in monolithic microwave integrated circuits
• The equipment developed can be used for material
research at all temperatures
• High temperature superconducting films have been used
as circuit switches using pulsed lasers to increase film
temperature above critical temperature
[.eW_ Rese;c.r(_ ,:[;e!;tPr
M a_e rials
1_89 Pqas+ 2 t_AS3-25929, 55-:;7 8_.7
NABA Co_tact - -'_omas Kss_aL
Small
Business
innovation
Research
Innovative High Speed Modem forSatellite Communications
SiCOM, Inc.
Scottsdale, AZ
INNOVATION
Very high integration ol modem functions and flexible user
programmability enabled by unique algorithm
development and hardware implementation
ACCOMPLISHMENTS
• Developed the first commercially available 155 Mbps ASIC-based modulator and demodulator to enable next generation
wideband video and data services
• Advanced the state of the art in modulation and coding
technology demonstrating significant power and bandwidth
efficient operation in a single integrated circuit
• Set the stage for successful integration of bandwidth on
demand into home and office via inexpensive wirelessmodems
COMMERCIALIZATION
• $5M in Phase III monies through 1997 from SiCOM andQuantum Partners, LLC
• Sales projections are $3M for 1998 and $8M for 1999
• Projected 1998 -1999 growth from 47 to 100 (116%) employees
• Companies that use or have placed orders for BitFLOW 155
Mbps modems include R. E. America, Andrew Corp., NuComm,
Dae Young, Raytheon TI, Wytek, t. O. Wave, VIS Technolgia,
Multimedia Broadband Technologies, Triton Network Systems,
Radyne and Texas Instruments
Lew,s _esearct" Center
Sate hie Cemmunicat=o_s
3-007
SiCOM's BitFLOW Variable Rate
Programmable DemodulatorUnit and the core ASIC
GOVERNMENT/SCIENCE APPLICATIONS
• Baseline modem for the NASA LeRC Direct Data
Distribution (D 3) project
• Applicable to International Space Station and Earth
Science missions which require wideband data
service
• BitFLOW will be used at Sandia Labs. Other
government agencies expressing interest includeDARPA, NRO, DISA, USSPACECOM, and CECOM
1994 F'nase II NAS3 E78=a 2..98
NAS_ Contact - "V*Onty _*:TdrO
{ 8w_Sar W _: 3r_ta( '. • [_c_ Pqtq,_:[_':
NASA/TM-- 1999-209649 39
TURBOMACHINERY
AND
PROPULSION SYSTEMS
Small
Business
Innovation
Research
Phase Doppler Particle AnalyzerAerometrics, Inc.
Sunnyvale, CA
INNOVATION
System that provides simultaneousmeasurement of fuel-particle size and velocity
in fuel injection systems
ACCOMPLISHMENTS
• Characterization of the complex turbulent flows in
gas turbine and rocket engines
• The system includes: transmitting and
receiving optics, a signal processor, system
software, and a fiber drive
• This non-intrusive device has created greatinterest in the commercial sector attested to
by its selection for the international Tanasawa Award
COMMERCIALIZATION
• Spray nozzle development for fuels, paints, agriculturalmaterials, and medical nebulizers
• Commercial sales - more than $25 million
(over $5M per year)
• Providing over 120 jobs at Aerometrics and its
suppliers and distributors
Lewis Researc_ 8e_lter
GOVERNMENT/SCIENCE APPLICATIONS
• Used in the characterization of particle
fields by NASA's Icing Technology Division
• Program uses include advanced subsonic
transport (AST) and high speed research (HSR)
1985 Pha_ae _AS3-25204 SS-39, 10 16'95
NASA ,3_n_cf - Wale ,_ t.ye:-_s
Small
Business
innovation
Research
Simultaneous Measurement of Temperature,Size, and Velocity of Drops in Sprays
Aerometrics, Inc.
Sunnyvale, CA
INNOVATION
An instrument which measures temperature, size
and velocity of drops in sprays using
rainbow refractomet ry/thermometry
ACCOMPLISHMENTS
• This laser-based, non-intrusive diagnostic instrument can
measure temperature (refractive index) of individual spherical
droplets in complex reactive sprays while simultaneously
measuring size and velocity
• Applications have included burning droplet streams, swirl-
stabilized spray flames, and multi-component non-reactive
sprays
COMMERCIALIZATION
• Received orders for $500K worth of equipment in July 1995
• Sold to universities (Carnegie Mellon) for use on spraycombustion studies
• Sold to aerospace industry for use in rocket injector studies
• Inquiries from Japan, China, France, and Korea
• Contributed to an expanded new location
GOVERNMENT/SCIENCE APPLICATIONS
• High Speed Research (HSR). Advanced Subsonic
Transport (AST), icing and in rocket injector research and
gas turbine combustion research
• Prototype rainbow thermometer delivered to Lewis and
integrated with existing two component Phase Doppler
Particle Analyzer
Lew;s _esearch Center
AerO3rr:,pL_ls=0r=
1_'39 Phase 2 NAS3-26248, SS-109 },29'9£
NASA :: or'ta¢:! - Mark Klein
NASA/TM-- 1999- 209649 43
sma, Single Lever Power Control for General AviationBusinessinnovation and Unmanned AircraftResearch Aurora Flight Sciences Corporation
Manassas, Virginia
INNOVATION
Pilot or Autopilot controls General Aviation or Unmanned Air
Vehicle (UAV) propulsion system via a Single Lever or a
Single Power Command using a FADEC (Full-Authority
Digital Engine Control) with optimal propeller/engine control
ACCOMPLISHMENTS
• Developed first FADEC with full-digital Single Lever Power
Control (SLPC) for General Aviation (GA) aircraft with
optimal propeller�engine control
• Developed and flight-tested the SLPC-FADEC system in
GA aircraft - showed over 20% fuel consumption
improvement
• Tested FADEC system wilh UAV engine in test cell to68,000 ft altitude
• FADEC-controlled engine propels the Perseus B high-altitude UAV to 60,000 It altitude
COMMERCIALIZATION
• Joint ventures with Athena Technologies combines SLPC
with advanced flight controls and FTC (Fault-tolerant
Control) algorithms
FADEC-controlled engines operated in excess of 500
hours in test cells and in flight
Ideal propulsion control unit for General Aviation naturally
aspirated and turbocharged singles, twins, turboprops and
other transportation propulsion systems
Aurora's Chiron aircraft with full-digital
Single Lever Power Control
GOVERNMENT/SCIENCE APPLICATIONS
• Currently being used in NASA's AGATE (Advanced
General Aviation Transport Experiment) for integrated
flight tests with all-digital cockpit technology components
• Potentially used in NASA's ERAST (Environmental
Research and Atmospheric Science Technology) UAV
program
_i_r_r_ ResP.F,_tCh Ce!lter
G_f:er_l Av:e, tior!
3-0,'_I
1994 Pnas@ ii, NAS3-2T814, 2,"99
NASA Con!aL'1 - Don_i'd Simoq
Compar_y Cc, ntacl - Beniami_'t _;:_s
SmallBusinessInnovationResearch
Unstructured Adapted MeshesCreare, Inc,
Hanover, NH
INNOVATION
Computer software for the solution of
compressible flows using unstructured grids
ACCOMPLISHMENTS
• Developed a general purpose computer program for
computational fluid dynamics
• Unstructured solution-adaptive grids have been applied to a
wide variety of problems including aircraft, turbomachinery,
automobiles, internal combustion engines, missiles,parachutes, etc.
COMMERCIALIZATION
• Commercialized as the product RAMPANT TM
• Well over $1M worth ot licenses for RAMPANT TM have
been sold
• Creare created a new software company, Fluent Inc. tomarket RAMPANT TM and several other CFD software
products that were developed, in part, with NASA SBIR
funding
• Fluent currently employs,over 200 people and has annual
revenues in excess of $30M. It was recently sold to Aavid
Thermal Technologies, which is a large company
Lewis Research Center
AeronB, utics
3-015
Mass fraction of exhaust gases and
prediction of Mach number duringconfined launch of a rocket
GOVERNMENT/SCIENCE APPLICATIONS
• Solution of fluid flow problems and the design of flight
vehicles using physical models that address turbulent
flows, heat transfer, compressible mixing, chemical
reaction, and flows with strong shocks
1987 _P_se II. NAS3-25785, 8:98
NABA Contac_ - Rodric_ Chim,_
Company Contact - Peg A,1.;kerson
NASA/TM-- 1999-209649 44
uma essAdvanced CFD Tools for Designing Combustion nnovation Systems & Materials Processing @Research Daat Research Corp.
Hanover, NH
INNOVATION I
A fast, compact, PC-based code for analyzing
combustion and materials processes
ACCOMPLISHMENTS
• A first of its kind, fast code for complex chemically reacting
flows in arbitrary geometries
• Ability to run efficiently on MS-Windows PCs
• Custom versions developed for optimizing certain
processes such as nozzle flows and fiber manufacturing
for composites applications
COMMERCIALIZATION
• Based on the developed technology, Daat produced Coolit
- a unique CFD code for electronics cooling applications
• Within two years, Coolit made major progress against well-
entrenched competition increasing its sales exponentially
and signing new clients world-wide
• Some of the world's best companies such as Boeing,
Raytheon, Lockheed-Martin, Teradyne, ECT Telecom and
many others now rely on Coolit for their thermal design
needs
Le¢._. Research Genter
Aerc,P,_u_i¢ s
3-02_"
Example of Results for Electronics Cooling
GOVERNMENT/SCIENCE APPLICATIONS
• Highly compact and efficient code for designing and
optimizing reactive flows in nozzles and in manufacturing
processes for composite fibers
• Used in support of high speed research (HSR), and
microgravity programs
• The commercial code, Coolit, is used in thermal design of
electronics
19')2 P_a._e tl #.AS.3-2725" !2'98
1992 Fh_=se II NAS3-26B,._8
NASA ,_:,:,q_ac: - A,non Oha,t,'Je_ ! Me.tier
Compare,, Colqtac! -Ar:k Dv nsKy
SmallBusinessinnovationResearch
Improved Electroformed Structural Copper andCopper Alloys for Rocket ComponentsElectroformed Nickel, Inc.
Huntsville, AL
INNOVATION
Improvements in mechanical properties of electrodepositedcopper by conversion of coarse columnar grains into fine equi-
axed grain structures and use of secondary strengtheningmethods such as alloying and dispersion strengthening
ACCOMPLISHMENTS
• Mechanical properties of electroformed copper equivalent
to those of wrought nickel have been demonstrated (a
50% improvement over prior electroformed copper)
• Elevated temperature ductility of electroformed copper to
500°F has been improved three fold
• Copper-platinum and copper-silver alloys have been
developed having potential for even higher temperature use
• A full scale regeneratively cooled copper tube bundle thrust •
chamber was fabricated entirely by electroforming with the
new copper to demonstrate that property degrading thermal
joining methods could be eliminated
COMMERCIALIZATION •
• To date $17K of these new materials have been sold to
NASA Lewis Research Center
• Pratt & Whitney is examining test samples for potential use •
in light-weight, high-performance reusable launch vehicles
C_]e!lr" F_÷se_r::t" (_'?r'ter
--_r t omacf_qe_y
3-¢':'0
NASA All Copper Compliant Tube RegenChamber Electroformed using new High
Strength Materials
NASA Tech Brief descriptions of the new materials are
being prepared as a beginning of a marketing effort.
Professional ioumal and symposium papers are
planned, as well as person-to-person discussions with
design engineers of major aerospace and defense contractors
Within the coming year, employment of additional staff
members is anticipated as this new material is required
under new contracts
GOVERNMENT/SCIENCE APPLICATIONS
Dialogue has already begun with Boeing's Rocketdyne
Division where Space Shuttle Main Engine upgrades are
in planning
Potential market will include DOD where new, improved
shaped charge liners for warheads is sought
_992 Phase li NAS3-273£,_, 5;99
NASA Coqtuct - Tim Srni_"
Company Cor_:acl - (3{en!_ Malone
NASA/TM-- 1999-209649 45
Small
Business
innovation
Research
Real-Time Sensor ValidationExpert Microsystems, Inc.
Orangevale, CA
INNOVATION
Real-time decision algorithm enables
very high reliability sensor failure detection for
safety critical control systems.
ACCOMPLISHMENTS
Prototype system validates 15 Space Shuttle Main
Engine (SSME) sensors in real-time
SSME prototype reliably detects sensor failures from,I)
Start to Shutdown command
, Embedded in Boeing's Advanced Fault Tolerant
Flight Computer and successfully tested
• Embedded in Lockheed-Martin's Modular Rocket
Engine Control Software and successfully tested
COMMERCIALIZATION
Follow-on contracts from NASA totaling $300,000
have created two full time equivalent jobs in 1997/98
Commercial applications in chemical process and
power generation industries anticipated
smcl sa_,n_m=_ tr,_no rtell i ,_=_,.m_S.*,..uU*m
......... ;
Space Shuffle Main Engine (SSME)Real Time Sensor Validation
GOVERNMENT/SCIENCE APPLICATIONS
• Under development for real-time Space Shuttle
telemetry data analysis and NASA mission
operations support
• Under evaluation for military aeropropulsion
system data monitoring
,-g_Wi$ Rese{irCil Ceq_!r
Space ProDuL._on
3-0 ! 2
1994 P'_ase . NAS3-27484 6.98
NASA Coqta$[ - .J_;rte Zakrajsek
Ccr_lps[_y Cor_[_:ict - _andail E_-ick!otd
Small
Business
Innovation
Research
Ice Detection Sensor System
Innovative Dynamics, Inc.
Ithaca, NY
INNOVATION
An integral sensor/de-icer system will enable pilots tovalidate de-icer inflation and to determine if accreted
ice has shed after system operation
ACCOMPLISHMENTS
41, The IDI sensor system will be integrated into B.F.
Goodrich pneumatic de-icers to achieve significant
advances in early ice detection, bringing ice detectiontechnology to the general aviation market at an affordable
price
COMMERCIALIZATION
@ System has potential market value of $40-100M
4, Market size of 20,000 to 50,000 general aviation aircraft
(1, Other applications include detection of ice on
runways, highways, bridges, antennas and powerlines
41' B.F. Goodrich has acquired a license to the
technology and patent rights for system
Automated ice protection system
GOVERNMENT/SCIENCE APPLICATIONS
41, Research supported by Icing TechnologyBranch within NASA Lewis Research Center
_1, Piper Malibu featured at September 94 icing
technology open house
Lewis Rese_r_;h !?,e_ter
Icing Techt_oiogy
1988 Pr_,=_se 2. NAS3-25966 SS-34 I0;_7;95
NASA Cot.tact -An_.lrew Reehorst
NASA/TM-- 1999-209649 46
SmallBusinessinnovationResearch
Fiber Optic Cable Feedthrough and HermeticSealing for Aerospace Environment
LiteCom, Inc.
Canoga Park, CA
INNOVATION
Fiber optic sealing matedal that provides cryogenic
hermetic sealing up to 10 -11 cc/sec Helium leak rate in
both feedthrou_lhS and connectors
ACCOMPLISHMENTS
• Designed and developed feedthroughs which
demonstrated 10 -t_ cc/sec helium leak rate at
temperatures from -196°C to +200°C
• Successfully used in vibration, thermal shock, salt spray,
humidity, mechanical shock, neutron fluence radiation,
gamma radiation, and ion radiation tests
• Created great interest in the commercial and military
underwater applications for hermetic seals
COMMERCIALIZATION
• Hermetic sealing material development for fiber optic
transmission between harsh environments such as
refineries, nuclear power plants, aircraft, mines, security
systems, petrochemical processing, ships, and corrosiveenvironments
• Commercial sales - more than $1M
• Providing 5 jobs at LiteCom and its suppliers
Lewi_ _esearch Car ter
3-009
Hermetically SealedConnector
GOVERNMENT/SCIENCE APPLICATIONS
• Provided hermetically sealed underwater connectors for
use with Navy submarines, submersibles, and remotely
operated vehicles
• Provided fiber optic hermetic sealed connectors for Sandia
Laboratory
• Potential for Space Station application
1990 Fq_e I; , NAS3-26611, 5'9_
NASA ,'. or'tac_ - An-:}' tanko,_k_
Company C_l:_at.t - Robe_¢ Car
SmallBusinessInnovationResearch
INNOVATION
Combining an adaptive grid method with Navier-
Stokes computer code for predicting ice growth
on aircraft and performance degradation
Unsteady Triangular Mesh/Navier-StokesMethod for Aerodynamics of Aircraft
with Ice AccretionNielsen Engineering & Research, Inc.
Mountain View, CA
..... ii ._'_'__"i
ACCOMPLISHMENTS
• Developed computation capabilities to study effects of ice
on the aerodynamics of aircraft wings<
COMMERCIALIZATION
• Received $42K in direct sales
• Improved capabilities in an area that did not previously
exist with the company; hence, company was able to
obtain additional work
NACA 0012 Airfoil with Simulated Glaze Ice
M =0.12,_ =4 °
GOVERNMENT/SCIENCE APPLICATIONS
Useful in studies and design for commercial and general
aviation for reducing ice accretion
Giel_r: _,eses, rch Cerlter
AepoRs_itic$
3-030
1988 Phsse II NAS3-26059, 1/99
NASA Contact - Mark _-_ta_cz:_k
Cbrnp__iny Corttaci - M!c'_ae R. Mer:der:ha !
NASA/TM-- 1999-209649 47
Small
Business
Innovation
Research
Catalytic Ignition for RotaryCombustion Engines
Precision Combustion
New Haven, CT
INNOVATION
Catalytic glow plugs and catalytic surface technology
for internal combustion engines and gas turbines
ACCOMPLISHMENTS
• Significantly reduced gaseous and white smoke emissions
in rotary engines, as well as improved efficiency and stability
• Demonstrated durability advantages of catalytic glow plugs vs.
conventional glow plugs
• Proved concept of using catalytic engine coatings under
severe thermal fatigue
COMMERCIALIZATION
• Advances in program led to developments in catalytic ignition
systems receiving $2,6M in further R&D investment from both
government and commercial sources
• Precision Combustion, Inc. is working with major diesel engine
manufacturers to implement catalytic glow plugs for new enginedesign, with Phase III investment more than $300K
• Company increased in size from 1 employee to 5 employees
Lewis Research Ceqter
/_ercprop_Jls;_q
Glowplug
GOVERNMENT/SCIENCE APPLICATIONS
• Technology enabled further catalytic combustor advances
by Precision Combustion, Inc. for DARPA, NASA, US
Army, and USAF
• Catalytic ignitors for improved combustion stability to
prevent flame out during rapid acceleration and
deceleration of aircraft engines
• Catalytic combustors for ultra-low emission gas turbineengines
1 £)86 Pha_e ;': NAS3-257_4. SS-i 60; 3:24/97
NASA Contact - Chi Mir=# Lee
Small
Business
Innovation
Research
A Novel Approachto Catalytic Combustion
Precision Combustion
New Haven, CT
INNOVATION
Advanced catalytic conbustor for aeropropulsion
and ground based engines
ACCOMPLISHMENTS
• Demonstrated Ultra-low NOx, CO, and Unburned Hydrocarbons
(UHC) emissions for High Speed Civil Transport applications
• No x emissions were demonstrated at steady-state to be 1/3 to
1/5 of regulatory targets
COMMERCIALIZATION
• Multimillion dollar long term catalytic combustor development
and supply agreement between Westinghouse PowerGeneration and Precision Combustion, Inc
• Precision Combustion Inc.'s catalytic combustor for Equivalent
Zero Emission Vehicles is in an automotive application engine
test program with Capstone Turbine Corporation
• Non-government Phase III funding of more than $500K for
ultra-low NOx emissions catalytic combustors for ground base
gas turbine hybrid electric vehicles
• Employment increased from 5 to 30 employees
,.ewis ReseaFC_'_ Ce_'lter
Aeropropu_s 3q
Catalytic Combustion Flame
GOVERNMENT/SCIENCE APPLICATIONS
• Ultra-low NOx aircraft and ground power catalyticcombustion
• Catalytic combustors for clean hybrid electric vehicles
• Ignition and combustion stability enhancement foraerospace engines
1990 Phase ii, NAS3-26614. SS-!61; 3;9"7
NASA Co!_tact • Ch:. Mir;$ Lee
NASA/TM-- 1999-209649 48
SmallBusiness_nnovationResearch
Flow in Turbine Blade PassagesScientific Research Associates, Inc.
Glastonbury, CT
INNOVATION
The use of refractive index matching laser velocimetry to
obtain detailed mean and turbulent flow fields
ACCOMPLISHMENTS
• Obtained knowledge of flow fields required to achieve goals
• Flow field measurements provided a nice compliment to
previously acquired heat transfer from a model of similar
geometry
• Simulations were compared to experimental velocity fields
• Combined computational-experimental program provided
new insight into structure of flow field
COMMERCIALIZATION
• Generated $240K in Government Non SBIR/STTR Funds
• UTRC collaborated in the program by providing model
geometry and heat transfer data
• Pratt and Whitney performed the computational calculations
Lew ':. Research Certer
Ae r4_q_uii,: s
Photomultiplier
Turbine Blade E]coo!ing passage _ i Outflow
Inflow
,¢: Ig::erJ
Laser-Doppler Velocimeter Set-up -
Forward Scattering
GOVERNMENT/SCIENCE APPLICATIONS
• New design tool for the development of turbine blade
internal cooling configurations
• Rotating flow field database useful for simulation codevalidation
1989 =hase ! , NAS3-262_rl 5'9.5
Nt*_A C*:_tacl " ¢"'_h# c-9=r'_att+
COmOar:_' tC_:ll3ct - Dr '-Iarold L Grubn
SmallBusinessinnovationResearch
High Temperature Oxidation-ResistantThruster Materials
Ultramet
Pacoima, California
INNOVATION
Very high temperature iridium/rhenium metal coatings andfree-standing structural shapes produced by a unique
chemical vapor deposition (CVD) process.
ACCOMPLISHMENTS
• Advanced the state-of-the art in materials and processes for the
fabrication of liquid bipropellant chemical rocket thrust chambers,
permitting operation at higher temperatures for longer time
periods and thereby providing a significant increase in pedormance
• Demonstrated process scaleup to larger chamber sizes
• Developed and characterized the fabrication process to permit
application of this technology to satellite and spacecraft propulsion
systems
COMMERCIALIZATION
• NASA, TRW/Lockheed Martin, Kaiser Marquardt/Hughes,
Aerojet, and Ultramet have invested nearly $20 million to
develop this technology
Flight qualification has been completed at Kaiser Marquardt,
with first flight on a Hughes communications satellite scheduled
in 1998
• To date, 4 jobs at Ultramet and 1 job at Kaiser Marquardt
have been created
Lew_ _e_earcb Cer'ter
M_ter_als
Molybdenum Mandrel and
Completed Ir/Re Chambers
GOVERNMENT/SCIENCE APPLICATIONS
• Through increased thruster pedormance,communications satellite owners/operators will realize
$30-60 million in added revenue
• Apogee kick and station-keeping thrusters for satellites in
geostationary orbit and thrusters for spacecraft
propulsion systems
• Rocket nozzles, turbomachinery, and aircraft
turbine engine components
_985 ='base I '_AS3-2_,203 SS-I?_ ! _'97
_',ASA Contact • Ste,,e S_.:t_neider
NASA/TM--1999-209649 49
SmallBusinessinnovationResearch
High Temperature Turbine BladesUltramet
Pacoima CA
INNOVATIONNet-shape fiber-reinforced metal matrix composite turbine
blades, produced by a unique chemical vapor infiltration
(CVl) process
ACCOMPLISHMENTS
• Evaluated continuous refractory fibers as strengtheningreinforcements for niobium metal matrix
• Developed controllable, repeatable process for infiltrating
niobium metal matrix into fiber preforms
• Ultimately spun off technology into fabrication of load-
bearing, hermetically sealed ceramic-to-metal joints for
use in high temperature propulsion systems
COMMERCIALIZATION
• Ceramic-to-metal joints fabricated for BMDO/Army TheaterHigh Altitude Air Defense System (THAADS), with $750K in
sales to date to propulsion contractor (Rocketdyne)
• Ceramic-to-metal joints fabricated for DOF_JNavy submarine
nuclear reactor program, with $500K in sales to date to
industry contractor (GE/Knolls Atomic Power Laboratory)
• To date, 3 new jobs have been created at Ultramet
Ceramic Composite Thrust Chamber
with Metal Flange Attachment
GOVERNMENT/SCIENCE APPLICATIONS
• Aerospace propulsion and power systems,
including intercept vehicles for missile defense,
nuclear submarine reactors, advanced aircraft
turbine engines and liquid rocket turbomachinery
Lewis Research Center
t,Aatedals_987 Phase ii NAS3-2565,_, SS-17B 8;'97
NASA C:br_tac_ - Jonr Kazarc'_!
NASA/TM-- 1999-209649 50
STRUCTURES
Small
Businessinnovation
Research
Design of Experiments ModuleAI Ware, Inc.
Cleveland, OH
INNOVATION
A general purpose computational method using artificial
intelligence that selects experiments required to develop a
design model
ACCOMPLISHMENTS
• Developed a Design of Experiments module for
enhanced computational methods
• Scientific community recognized this product as a very
useful contribution for re-designing experiments and
hence reducing experiment costs
• Company was selected by readers of R&D magazine
as a winner in the 1994 R&D ELITE Awards Program
COMMERCIALIZATION
• Experiments module is tentatively scheduled for
commercial release in mid-1995 along with theintroduction of CAD/Chem Version 4.2
• Diverse customer base includes: pharmaceuticals &
medical (Eli Lilly and Company), chemicals (S.C.
Johnson Wax),, plastics (B.F. Goodrich & Dow
Chemical), paint & coatings (The Gtidden Paint
Company)
• Contributed $100K to sales, and this contribution is
increasing
I.ew=s rqesearch Center
St:u_<,res
Design of Experiments Module
GOVERNMENT/SCIENCE APPLICATIONS
• The computer program which incorporates
artificial intelligence can be applied to any
experimental designing used in the scientific andresearch communities
• This method is presently being used in Lewis
Research Center's Structural Analysis program
• Also used at Wright Patterson AFB in the
composites area
1990 PhaGe 2. NAS3-76657 SS-`97 8.?,96
NASA Con'act - Lasz.ie Berke
Small
Businessinnovation
Research
Autosolid
Cadetron, Inc.
Atlanta, GA
INNOVATIONAn expert system that utilizes CAD capabilities to create
a finite element model for use by those who are not experts
in Finite Element analysis
ACCOMPLISHMENTS
• A solid modeler was developed and integrated with an
internal advisory expert system to automatically transform itinto a finite element model and to perform structural
analysis
COMMERCIALIZATION
• The product caught the interest of AUTODESK, the world's
largest CAD/CAM software company before the contract
end date and they bought Cadetron
• The solid modeler was first released as AUTOSOLID then
as the "Advanced Modeling Extension" (AME) to the
AutoCAD product. Sales of this product resulted in several
million dollars of revenue.
Information Flow of Finite Element Analysis
GOVERNMENT/SCIENCE APPLICATIONS
• Has been used in NASA Lewis's structural analysis
research
• Innumerable applications for product design within the
AutoCad system
Struck_re. _.
3. £-38
I,985 Phase 2:NAS3-25150 SS-12_:; 312,98
NASA Contact • L_SZO Be:Ke
Co,'-;p,!lny Contact - Robert, _nl
NASA/TM-- 1999-209649 53
SmallBusiness
innovation
Research
AUTODESIGN
Structural Analysis Technologies, Inc.
Santa Clara, CA
INNOVATION
Integration of solid modeling, structural analysis/optimization
with Expert System Advisor
ACCOMPLISHMENTS
• AUTGDESIGN is a structural optimization and design software
which is unique in the market because of its Expert System
knowledge based content
COMMERCIALIZATION
• Structural Analysis Technologies has partnered with
AUTODESK, the world's largest CAD/CAM software company,to market AUTODESIGN
• Approximately 500 copies were sold by Structural Analysis
Technologies, with sales totaling nearly $2 M
• SAT, together with AUTODESK are part of the winning team for
the $900 M Navy NAVFAC software contract. SAT's portion of
the contract is $5M with a maximum up to $7M
AUTODESlGN architecture
GOVERNMENT/SCIENCE APPLICATIONS
• Used at Lewis Research Center and Edwards AFB in
design of new generation aerospace structures
• Used by Hughes Aircraft, TRW, Applied Materials,
Lockheed, Sandia Labs, and Kelly AFB, as well as other
firms and government organizations for mechanical and
aerospace design
LeWiS Rec_e3!'ch Cer_t6_"
St_'_ctura$
1987 Phase li NAS3-25642, SS-28.8/23i97
N_,SA Cor_tac[ - Laszlc, Berke
Small
BusinessInnovation
Research
High Reliability Long-Term LubricatorsThe Technology Partnership
Grosse lie, MI
INNOVATION
Dispensing lubdcant for multi-year durations using
the viscoelastic effects of polymers
ACCOMPLISHMENTS
• Developed long term time-dependent shrink-polymers for
dispensing lubricants
• Validated a new use for shrink-polymers as implants for long
term drug-infusion pumps
• Patents obtained for new shrink-polymer applications
COMMERCIALIZATION
• A major automotive supplier has committed for $500K in follow-
on funding for an annual automotive market estimated at $100M
annually
• Major drug companies are evaluating a universal drug-
dispensing implant that uses viscoelastic technology
• Subsequent Phase I and II SBIR awards from both Army Tank
automotive and Armaments Command (TACOM) and the Air
Force based on shrink-polymers
Photo courtesy of TACOM - Glen Steele
Shrink.Polymer Dispenser
GOVERNMENT/SCIENCE APPLICATIONS
• Assured lubrication of satellite spin-motors with 80%
reduction in lift weight over mechanical lubricators
• Lubricator has the potential to make substantial
improvements in maintenance costs and reliability of
U,S, Army tactical vehicles
Lewis Research Car_ter
Maier:als
'19#2 Phase I, qAS3-2(_844, SS-181.8,'97
NASA C3ntact.._obert F'_,saro
NASA/TM-- 1999-209649 54
MICROGRAVITY
SmallBusinessinnovationResearch
A Capacitive Void Fraction Instrument forTwo-Phase Flow in Microgravity
Creare, Inc.
Hanover, NH
INNOVATION
Non-intrusive instrument for measurement of
volume-averaged or local void fraction with
refrigerants (dielectric fluids)
ACCOMPLISHMENTS
• Proved non-intrusive design approach
• Developed stable, accurate electronics and signal
conditioning
• Demonstrated instrument on microgravity aircraft
• Space-qualified instruments delivered
• Continuing to support microgravity aircraft flights
in 1998/99 (KC-135) with the design/development of
instruments of various internal diameters
COMMERCIALIZATION
• Sold approximately $500K worth of these instruments toNASA for various science missions to date
• Instrument can be used in a gravity environment. Have
had negotiations with some companies for use in gravity
Space-Qualified Version of CreareVoid Fraction Instrument
GOVERNMENT/SCIENCE APPLICATIONS
• Used in microgravity science missions aboard the
NASA KC-t35 aircraft:
- To measure flow characteristics (local/avg. void
fractions and wall shear stress) in a R-134a
refrigerant loop by NASA LeRC Microgravity Division
- To measure flow characteristics in R-134a and R-12
refrigerant loops by NASA JSC Crew and Thermal
Systems Division (with Texas A&M University)
NASA/TM-- 1999-209649 57
REPORT DOCUMENTATION PAGE FormApproved
OMB No. 0704-0188
Public reporting burden for this COllection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources,gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of thiscollection of information, _ncluding suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 JeffersonDavis Highway. Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503,
1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE
December 1999
4. TITLE AND SUBTITLE
SBIR Success Stories at NASA Glenn Research Center
6. AUTHOR(S)
Walter S. Kim, Dean W. Bitler, George M. Prok, Marie E. Metzger,
Cindy L. Dreibelbis Meghan R. Howe, and George D. Novak
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)
National Aeronautics and Space Administration
John H. Glenn Research Center at Lewis Field
Cleveland, Ohio 44135-3191
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)
National Aeronautics and Space Administration
Washington, DC 20546-0001
11. SUPPLEMENTARY NOTES
3. REPORT TYPE AND DATES COVERED
Technical Memorandum
5. FUNDING NUMBERS
WU-295-01--01-00
8. PERFORMING ORGANIZATIONREPORT NUMBER
E-11997
10. SPONSORING/MONITORINGAGENCY REPORTNUMBER
NASA TM-- 1999-209649
Walter S. Kim and Dean W. Bitler, NASA Glenn Research Center: George M. Prok, Marie E. Metzger,
Cindy L. Dreibelbis, Meghan R. Howe, and George D. Novak, Omni Corporation, 21000 Brookpark Road, Cleveland,
Ohio 44135. Responsible person, Walter S. Kim. organization code 9400, (216) 433-3742.
12a. DISTRIBUTION/AVAILABILITY STATEMENT
Unclassified - Unlimited
Subject Categories: 01 and 31 Distribution: Nonstandard
This publication is available from the NASA Center for AeroSpace Information, (301) 621-0390.
12b. DISTRIBUTION CODE
13. ABSTRACT (Maximum 200 words)
This booklet of success stories summarizes the NASA Glenn Research Center's accomplishments and successes by the
Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) programs. These success
stories are the results of selecting projects that best support NASA missions and also have commercialization potential.
Each success story describes the innovation accomplished, commercialization of the technology, and further applications
and usages. The company name and the NASA contact person are identified to encourage further interest and communica-tion to occur.
14. SUBJECT t_HMS
Aeronautics; Subsonics systems; Materials; Power; On-board propulsion; Instrumentation
controls; Communications; Turbomachinery propulsion system Structures; Microgravity
17. SECURITY CLASSIFICATION
OF REPORT
Unclassified
NSN 7540-01-280-5500
18. SECURITY CLASSIFICATION
OF THIS PAGE
Unclassified
19. SECURITY CLASSIFICATION
OF ABSTRACT
Unclassified
15. NUMBER OF PAGES
6516. PRICE CODE
20. LIMITATION OF ABSTRACT
Standard Form 298 (Rev. 2-89)
Prescribed by ANSI Std. Z39-18298-102